Table of Contents - Auto-Kabel · 2019-09-02 · 5-14 QAV-1 Basic Checklist 5-15 QAV-2 Process Audit Checklist 5-16 SAP Template 6 Supplement 6-1 ... etc.) to be used when safety,

Table of Contents

HSQM-TOC Page 1/3 04/01/19

Table of Contents

1 Preface 1-1 Structure of SQM 1-2 SQM Outline

2 General

2-1 Quality Control Regulations and Minimum Quality System Requirements 2-1-1 Quality Control Regulations and Minimum Quality System Requirements Procedure 2-1-2 Corrective Action System 2-1-3 Operation Standards, Training, and Process Job Qualification 2-1-4 Process Control 2-1-5 Change Point Control 2-1-6 Supplier Management 2-1-7 Lot Control and Traceability 2-1-8 Inspection, Test, and Calibration 2-1-9 Suspect and Nonconforming Part and Abnormal Process 2-1-10 Organization 2-1-11 Quality Systems and Policies 2-1-12 Preventive Maintenance 2-2 MPR (Minimum Process Requirements) Procedure 2-3 China Compulsory Certification (CCC) 2-4 Bar Code Standard 2-5 Designation of Quality Representative 2-6 Supplier Quality Assurance Visit (QAV)

3 New Model Stage

3-1 CRF (Countermeasure Request Form) 3-2 Inspection Data 3-3 SAP (Specified Action Plan) 3-3-1 SAP Components 3-3-2 SAP Procedure 3-4 Supplier Part Schedule (SPS) Procedure 3-5 Part Maturation Definitions 3-6 Part Approval 3-7 PFMEA (Process Failure Mode and Effect Analysis)

3-8 PQCT (Process Quality Control Table) 3-9 Inspection Fixture Design Guideline

3-10 PAC-V (Process Assurance Capability Verification) 3-11 TPR (Technical Part Review) 3-12 Limit Sample 3-13 Master Sample Development

3-14 New Model Receiving Inspection 3-15 Surface Finish 3-15-1 Surface Finish Procedure 3-15-2 Minimum Tooling Specifications for Surface Finish Parts 3-15-3 Gloss Meter Correlation Requirements 3-16 Traceability and Lot Control 3-17 PV (Part Validation) Testing

Table of Contents


3-17-1 PV (Part Validation) Testing Procedure 3-17-2 PV Test Risk Analysis Form Guidelines

4 Mass Production Stage 4-1 Change Point Control (IPPAAR/IPP) 4-2 Honda Supply Parts Trouble Management

4-2-1 Honda Supply Parts Trouble Management 4-2-2 DSPS Flow 4-2-3 JSPS Flow

4-3 Nonconforming Product 4-4 Corrective Action Report

4-4-1 5P (5 Principles for Problem Solving) 4-4-2 Challenge Quality (CQ) Process Overview

4-5 Index System 4-6 Controlled Containment 4-7 Sort Label

4-8 Identification Control 4-9 MTR (Minimum Test Requirement) 4-9-1 MTR (Minimum Test Requirement) Procedure 4-9-2 Minimum Test Requirements Electro-Mechanical and Mechanical Assemblies 4-9-3 Minimum Test Requirements SRS Assemblies 4-9-4 Minimum Test Requirements Suspension Damper Assemblies 4-10 Non-Destructive Testing (NDT) Requirements

5 Reference/ Forms 5-1 5P (5 Principles for Problem Solving) 5-2 CRF (Countermeasure Request Form) 5-3 Data Sheets 5-3-1 Inspection Data 5-3-2 Receiving Inspection Data 5-3-3 Regulation Data 5-4 Inspection Fixture 5-4-1 Gage R&R Worksheet – Long Method 5-4-2 Gage R&R Worksheet – Short Method 5-4-3 Supplier Inspection Fixture Concept 5-4-4 Supplier Inspection Fixture 5-5 IPPAAR/ IPP (Initial Production Parts Advance Approval Request/ Initial Production Parts) 5-5-1 IPPAAR 5-5-2 Initial Production Parts Quality Assurance Declaration 5-5-3 IPP Tag 5-6 Lot Control and Traceability 5-6-1 LNDD (Lot Number Display Detail) 5-6-2 Lot Control Notification Example 5-6-3 PDF (Process Display Form) 5-7 MPR (Minimum Process Requirements) Checksheets 5-7-1 Casting 5-7-2 Error Proofing 5-7-3 Fluid Fill 5-7-4 Heat Treatment

Table of Contents


5-7-5 Hot Plate Welding 5-7-6 Molding 5-7-7 Label 5-7-8 Machining 5-7-9 Painting 5-7-10 Part Marking 5-7-11 PCB 5-7-12 Sonic/ Vibration/ Friction Welding 5-7-13 Stamping 5-7-14 Torque 5-7-15 Weld 5-7-16 Wire Harness and Electrical Connection

5-7-17 Leak Test 5-7-18 Traceability

5-8 PQCT (Process Quality Control Table) 5-9 PV (Part Validation) Testing

5-9-1 PV Testing Blank and Numbered 5-9-2 PV Testing Schedule and Results Summary

5-10 Styling Parts Guideline (Surface Finish) 5-10-1 Electrode Review 5-10-2 Texture Indication Map 5-10-3 Tool Trial History Sheet 5-10-4 Appearance Part Tool Detail Sheet

5-11 PAC-V (Process Assurance Capability Verification) Sheet 5-12 Sourcing QAV 5-13 Global QAV-1

5-13-1 Table of Findings 5-13-2 Auditor Report

5-14 QAV-1 Basic Checklist 5-15 QAV-2 Process Audit Checklist 5-16 SAP Template

6 Supplement 6-1 NA SQM Supplier Record Retention Requirement Matrix 6-2 Honda Supplier Quality Manual Revision Information List 6-3 Acronyms and Definitions 6-4 HSQM Continuous Improvement Flow 6-5 Plant Codes 6-6 Factory Guest Engineer (FGE) 6-7 Supplier Quality Performance Rating 6-8 Master List

Preface

HSQM-0126 Page 1/1 04/01/19

Purpose This manual is referred to as Supplier Quality Manual (referred to as SQM) and is a “specification” per the NAPSA; North American Purchase and Sale Agreement “to which compliance must be maintained for establishment of process(es) to provide high quality that satisfies and exceeds the expectations of Honda product users”.

Scope The SQM applies to all Honda Suppliers and Sub-Tier Suppliers to

Honda. The scope of SQM includes quality assurance activities performed by suppliers to ensure the appropriate quality of delivered parts.

Roles of SQM The SQM is a specification that sets Supplier Quality Requirements and

Expectations, agreed upon between Honda and suppliers. The SQM is designed with a view to provide requirements and supplemental information in order for parts and suppliers to meet quality assurance expectations.

Confidentiality Honda and suppliers agree to take the same care to preserve the confidentiality

of each other's confidential information and will not disclose such information to any third party without the prior permission of the other party. SQM is owned and controlled by Honda. All contents of SQM shall be maintained and stored in a safe and controlled manner. Suppliers may replicate sections and pages ofSQM for the purpose of training use or as reference, however proper custody and control must be maintained such that downloads and printouts are updated to the latest revision. SQM contains confidential and proprietary information of Honda, and as a general rule, it will not be disclosed to any individual or organization other than those who are suppliers without prior written approval of Honda. However, if it is required to perform operations and tasks, such as dissemination to second and sub-suppliers, the information may be shared under the sole responsibility of the disclosing suppler by identifying the person responsible for the control and by exercising appropriate discretion and confidentiality of the information.

Public Quality Standards

Reference section 2.1.1 - Quality Control Regulations, Conformance to ISO9001, ISO14000 and ISO26262.

Revision Honda may revise or update the SQM as necessary. Honda notifies suppliers of such revision or update of SQM, and it takes effect at the specified date.

Structure of SQM

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SQM Outline

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No. Document Title Overview

1 Preface Outline the purpose, scope, system, and image, etc. of the production process.

2 General

2-1

Quality Control Regulations and Minimum Quality System Requirements Suppliers shall conform to the requirements described by latest ISO standards.

2-1-1

Quality Control Regulations and Minimum Quality System Requirements Procedure

Specific procedures, forms, timing and other requirements used by Honda and required of the supplier are detailed in this manual. These are in addition to the requirements of ISO and covers the continuing quality assurance and performance required of the supplier on all parts, materials, and services,

2-1-2 Corrective Action System

Supplier shall create and maintain a written or electronic corrective action system flow/process. Supplier shall keep a record/log of customer reported problems including problem description, cause, corrective action, reply due date, planned and actual implementation dates, and how the effectiveness of the corrective action was confirmed before closure.

2-1-3

Operation Standards, Training and Process Job Qualification

1) The supplier shall have a documented system that describes how operation standards are created, reviewed, approved, displayed and revised. 2) There shall be a defined process and procedure by which individuals are trained and their qualification to perform the job process is evaluated.

2-1-4 Process Control

The supplier shall create and maintain PFMEAs, PQCTs, Error Proofing & Inspection Devices (Poka Yokes) and conform to the Data Collection, First Piece Confirmation and Retainment and Process and Equipment Check Sheet Requirements listed in this manual.

2-1-5 Change Point Control

The supplier shall have a documented change point control system that records all changes in a part or process from a sub-supplier, changes in manufacturing conditions, change in source of materials or components. Records shall include description of the change, approval level required, approval status, initial production part lot numbers and shipping data.

2-1-6 Supplier Management Defines the Supplier's Quality Management Requirements, Component Part, and Material Quality Assurance Requirements.

2-1-7 Lot Control and Traceability

Lot Control and Traceability require identification of the component parts for Honda products, so if any problems occur due to those component parts, it can be traced, isolated, contained and corrected. Honda requires all parts to conform to the appropriate level of lot control as determined by Honda.

2-1-8 Inspection, Test and Calibration

The supplier shall conduct periodic part confirmation and specification tests including dimensional layouts, burn resistance tests, and annual photometric testing. Supplier shall have a documented gauge repeatability and reproducibility program for all tools, inspection devices, and check fixtures used for critical measurements or those designated by Honda.

2-1-9

Suspect and Nonconforming Part and Abnormal Process

1)The supplier shall have a documented procedure(s) describing how suspect and nonconforming components and materials, work in process, and finished goods are identified (tags, red bins, etc.), how such goods are isolated from similar goods whose status is not suspect or nonconforming, how disposition is determined for such goods, and triggers to escalate the disposition process. Roles and responsibilities shall be clearly identified. 2) The supplier shall have a documented procedure describing necessary notifications, approvals and safeguards required each time an abnormal process is used. The procedure shall link to or refer to the supplier's change point control requirements and Honda's IPPAAR/IPP requirements. The procedure shall describe roles and responsibilities, including the authority for approval of quality safeguards, and the authority for evaluating any potential impact to capacity and delivery.

2-1-10 Organization

1) The supplier shall identify and document roles and responsibilities for each division, department, or other group within the organization. 2) The supplier shall analyze periodically internal and external part nonconformities, audit results, and other quality related issues, identify production processes and/or quality systems that are deficient and create a plan to improve those processes and/or systems

SQM Outline

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2-1-11 Quality Systems and Policies

1) The supplier shall establish and document general policies and procedures applicable to all relevant processes. 2) The supplier shall establish a formal problem solving method (5P,8D, etc.) to be used when safety, quality, warranty, and delivery problems occur. 3) All relevant personnel shall be trained and qualified for these general policies and the selected problem solving method in a similar manner to specific job process training.4) The supplier shall develop and implement quality metrics to manage and control quality performance at the plant, departmental, and production line level.

2-1-12 Preventive Maintenance

The supplier shall have a documented schedule for periodic maintenance required for all production process equipment and fixtures. At a minimum, PM schedule shall be based on equipment manufacturer recommendations and past problem history. Predictive maintenance programs may also be used. Where possible, the schedule shall be based upon running time or machine cycles rather than calendar time.

2-2 MPR (Minimum Process Requirements) Procedure

Define the minimum controls and methods Honda requires in applicable manufacturing processes. The supplier must assure the minimum process requirements are built into the applicable processes. Requirements must be reflected to each manufacturing process and into the PQCT.

2-3 China Compulsory Certification (CCC) Clarifies specific Honda requirements that must be met for parts that have CCC requirements.

2-4 Bar Code Standard Barcodes must conform to latest ANSI revisions - Guideline for Bar Code Print Quality

2-5 Designation of Quality Representative Quality Representatives to be specified in Supplier Relationship Management database

2-6 Quality Assurance Visit (QAV) Section describes Quality Assurance Visit (QAV) types and scope

3 New Model Stage

3-1 CRF (Countermeasure Request Form) Suppliers will utilize CRF “form” for requesting a specification and/or drawings change.

3-2 Inspection Data

Supplier shall take data to guarantee the process consistently produces good parts. Supplier shall collect and retain appropriate data to validate parts and production regardless of Honda's request for data submission. The frequency of taking data depends on the process capability.

3-3 SAP (Specified Action Plan)

The SAP is used to establish goals, break goals into tasks or jobs, define when to perform the tasks, assign responsibility for completing the tasks and track and evaluate the progress of each step.

3-3-1 SAP Components

The SAP shall include project goal setting, job tree, progress tracking, organization, evaluation process, SAP within the supplier organization, APQP deficiency, evidence justifying the status and visual management and reporting.

3-3-2 SAP Procedure Suppliers shall create a SAP for each new model project. Based on part rank and each plant's requirements, suppliers may be required to periodically submit the SAP to Honda for review.

3-4 Supplier Part Schedule (SPS) Procedure

Suppliers are responsible to document and communicate New Model part development schedules to Honda Purchasing. This is required for all new or changed parts that apply from the launch of a new model.

3-5 Part Maturation Definitions

Provides a description of part maturation levels based on status/level of equipment, tooling, part dimension, texture, fixture/jig, testing device, process, material, manpower and manufacturing/build location.

3-6 Part Approval

This section describes requirements & process to approve that a Suppliers part can consistently meet the quality requirements, and the part can be used in mass production. It applies to new and changed parts for new model..

3-7 PFMEA (Process Failure Mode and Effect Analysis)

Suppliers are to create and maintain PFMEAs. The supplier shall have a documented system that describes how PFMEAs are created, reviewed, approved and revised.

3-8 PQCT (Process Quality Control Table)

Suppliers are to create and maintain PQCTs. The supplier shall have a documented system that describes how PQCTs are created, reviewed, approved and revised. A primary input into the creation of the PQCT shall be the PFMEA.

SQM Outline

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3-9 Inspection Fixture Design Guideline

This guideline is intended as a reference for all fixtures used to assure the quality of parts purchased by Honda. It is intended to produce accurate and consistent quality inspections of Honda parts, regardless of the fixture supplier or manufacturing method.

3-10 PAC-V (Process Assurance Capability Verification)

Is a form/sheet issued by Honda and is used to ensure identified critical control points (CCPs) have appropriate process controls planned prior to tooling go timing and actual process capability and parts are confirmed prior to Mass Production.

3-11 TPR (Technical Part Review)

Evaluates a supplier/part design and process planning, process maturation, process verification and stabilization. Parts are selected for TPR based on new model part rank, new supplier to Honda, new technology/feature, new material, new manufacturing process, new system, high warranty rate or supplier black box design.

3-12 Limit Sample Is used for parts to define allowable limit that cannot be measured or counted (e.g. appearance or items that have a judgement factor involved).

3-13 Master Sample Development

Is used for parts to define requirement (target) that cannot be measured or counted (e.g. appearance or items that have a judgement factor involved).

3-14 New Model Receiving Inspection

Used to confirm that purchased parts used for Honda new model trial events meet delivery and quality requirements. This procedure applies to all parts used for new model applications.

3-15 Surface Finish Specification clarification used for appearance parts or parts with texture. (e.g. seats, dash panels, door panels, etc.)

3-15-1 Surface Finish Procedure Defines process/requirements for parts with texture. (e.g. seats, dash panels, door panels, etc.)

3-15-2

Minimum Tooling Specfications for Surface Finish Parts Requirement is to ensure the tool surface accurately represents Honda styling data

3-15-3 Gloss Meter Correlation Requirements

Supplier is responsible to identify gloss meter correlation requirements through review of drawing and specification information. Supplier submits gloss meter to North American Purchasing, SQD Color Group, for correlation study.

3-16 Traceability and Lot Control

Suppliers are to manufacture parts for Honda in discrete and identifiable groups, called lots. Suppliers must control lots process to process. In addition, component parts and materials used in each step of the manufacturing process must be traceable to the lot.

3-17 PV (Part Validation) Testing This section applies to parts that have any testing requirements listed on the drawing or specs.

3-17-1 PV (Part Validation) Testing Procedure

Defines process/requirements for parts that require PV testing. .Product Validation testing is required by Honda for a supplier to demonstrate the mass production processes that produce a part meet or exceed the minimum testing requirements.

3-17-2 PV Test Risk Analysis Form Guidelines Defines process/requirements for PV testing that has been delayed or has had a failure.

4 Mass Production Stage

4-1 Change Point Control (IPPAAR/IPP) See IPPAAR/IPP

4-2 Honda Supply Parts Trouble Management This section includes information regarding the Honda Supply Parts Trouble flow

4-2-1 Honda Supply Parts Trouble Management Describes the process that shall be followed for problems related to parts that are DSPS/JSPS.

4-2-2 DSPS Flow DSPS flow shall be followed when a parts problem is identified from a Domestic Supply Parts Supplier.

4-2-3 JSPS Flow JSPS flow shall be followed when a parts problem is identified from a Japan Supply Parts Supplier.

4-3 Nonconforming Product

Definition of nonconforming product and supplier requirements when supplier is notified of or identifies nonconforming product. Supplier must notify Honda if containment is lost. Supplier must analyze cause, implement corrective actions, report results to Honda, and reflect results at supplier. Outlines requirements for supplier reporting and how charges are applied.

SQM Outline

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4-4 Corrective Action Report

Corrective action reports shall contain the problem description, cause, corrective action, reply due date, planned and actual implementation dates, and confirmation method of the corrective action.

4-4-1 5P (5 Principles for Problem Solving)

The 5P is an in-depth reply to an HTR related to a high impact problem, A rank issue, or as required by Honda. The 5P will cover the problem analysis, Countermeasure, Effectiveness, and Countermeasure follow-up.

4-4-2 Challenge Quality (CQ) Process Overview

The challenge quality process shall apply to any market claim parts returned under the Challenge Quality Program.

4-5 Index System

System used to evaluate a supplier's Quality Management System performance and classify severity of part problems found. Summarizes the potential impacts of suppliers on Honda and Honda's customers

4-6 Controlled Containment Suppliers shall follow controlled containment procedures defined in the SQM to ensure only good parts are shipped to Honda by means of secondary inspection.

4-7 Sort Label Sort labels, as well as ASN notification, shall be used by suppliers to indicate any containment activity that takes place during normal manufacturing processes.

4-8 Identification Control Honda shall tell suppliers when identification codes are required for different part types being delivered to Honda.

4-9 MTR (Minimum Test Requirement)

All parts shall meet the minimum test requirements. These requirements were established to find quality defects that otherwise may not be found. Honda may require additional analysis when necessary.

4-9-1 MTR (Minimum Test Requirement) Procedure

MTR procedure applies to all OEM purchased parts and material shipped to North American Honda Plants. May be used to investigate market returns or factor returns when requested.

4-9-2

Minimum Test Requirements Electro-Mechanical and Mechanical Assemblies

Outlines the Minimum Test Requirements for handling/analysis/testing of all electro-mechanical and mechanical assemblies. Test items and requirements are determined by Failure Rank.

4-9-3

Minimum Test Requirements SRS Assemblies

This requirement for SRS control units provides minimum data that must be recorded, tests and inspections that are required, part storage, and reporting criteria.

4-9-4

Minimum Test Requirements Suspension Damper Assemblies

This requirement for suspension damper assemblies outlines the minimum data that must be recorded, required tests and inspections, dimensional layout, on vehicle noise testing, and reporting criteria.

4-10 Non-Destructive Testing (NDT) Requirements

Outlines requirements for nondestructive testing as an alternative to destructive testing and driver checking. Provides NDT requirements for projection welding.

5 Reference/ Forms

5-1 5P (5 Principles for Problem Solving) FORM

5-2 CRF (Countermeasure Request Form) FORM

5-3 Data Sheets

5-3-1 Inspection Data FORM

5-3-2 Receiving Inspection Data FORM

5-3-3 Regulation Data FORM

5-4 Inspection Fixture

5-4-1 Gage R&R Worksheet - Long Method FORM

5-4-2 Gage R&R Worksheet - Short Method FORM

5-4-3 Supplier Inspection Fixture Concept FORM

5-4-4 Supplier Inspection Fixture FORM

5-5 IPPAAR/ IPP (Initial Production Parts Advance Approval Request/ Initial Production Parts)

5-5-1 IPPAAR FORM

5-5-2 IPP Tag FORM

5-6 Lot Control and Traceability

SQM Outline

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5-6-1 LNDD (Lot Number Display Detail) FORM

5-6-2 Lot Control Notification Example FORM

5-6-3 PDF (Process Display Form) FORM

5-7 MPR (Minimum Process Requirements) Check sheets

5-7-1 Casting FORM

5-7-2 Error Proofing FORM

5-7-3 Fluid Fill FORM

5-7-4 Heat Treatment FORM

5-7-5 Hot Plate Welding FORM

5-7-6 Molding FORM

5-7-7 Label FORM

5-7-8 Machining FORM

5-7-9 Painting FORM

5-7-10 Part Marking FORM

5-7-11 PCB FORM

5-7-12 Sonic/ Vibration/ Friction Welding FORM

5-7-13 Stamping FORM

5-7-14 Torque FORM

5-7-15 Weld FORM

5-7-16 Wire Harness and Electrical Connection FORM

5-7-17 Leak Test FORM

5-7-18 Traceability FORM

5-8 PQCT (Process Quality Control Table) FORM

5-9 PV (Part Validation) Testing

5-9-1 PV Testing Blank and Numbered FORM

5-9-2 PV Testing Schedule and Results Summary FORM

5-10 Styling Parts Guideline (Surface Finish)

5-10-1 Electrode Review FORM

5-10-2 Texture Indication Map FORM

5-10-3 Tool Trial History Sheet FORM

5-10-4 Appearance Part Tool Detail Sheet FORM

5-11

PAC-V (Process Assurance Capability Verification) Sheet FORM

5-12 S-QAV FORM

5-13 GQAV-1 5-13-1 Table of Findings FORM

5-13-2 Auditor Report FORM

5-14 QAV-1 Basic Checklist FORM

5-15 QAV-2 Process Audit Checklist FORM

5-16 SAP Template FORM

6 Supplement

6-1

NA SQM Supplier Record Retention Requirement Matrix

Suppliers must retain all records (electronic, physical, etc.) in compliance with the record retention matrix. All records can be immediately destroyed upon expiration of record timing in accordance to supplier internal standards.

SQM Outline

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6-2

Honda Supplier Quality Manual Revision Information List Revision history of the Supplier Quality Manual.

6-3 Acronyms and Definitions Honda uses many Acronyms throughout the various business practices. This list should be used as a reference for the acronyms that will be encountered.

6-4 HSQM Continuous Improvement Flow

The HSQM is developed by a continuous improvement method (input, evaluation, decision making, etc.) with stakeholders and users making beneficial changes. Maintaining the effectiveness of the HSQM depends on the continual input and evaluation from all North America Honda plants.

6-5 Plant Codes A list of plant codes/identifiers used by Honda to indicate various plants.

6-6 Factory Guest Engineer (FGE)

The FGE program allows suppliers access to build events at Honda, during new model development and mass production when necessary.

6-7 Supplier Quality Performance Rating

Honda Purchasing and/or Quality groups go through the process of measuring suppliers' quality performance. This process has two parts - forming the ratings and Honda subsequent actions.

6-8 Master List List of NA SQM changes/additions/deletions/etc

Quality Control Regulations and Minimum Quality System Requirements __________________________________________________________________

HSQM-0002 1/16 04/01/2019

2.1.1 Quality Control Regulations

This regulation covers the continuing quality assurance and performance required of the supplier on all parts, materials and services ordered from the supplier by Honda. This regulation is a part of the purchase agreement between the supplier and Honda and is supplemental to any other purchase terms or conditions. This regulation is intended to help assure the parts, materials and services meet the specifications established by Honda's purchase orders, engineering drawings, quality requirements and standards, government regulations and/or other agreements between Honda and the supplier. This regulation is applicable to the parts, materials and services Honda orders from the supplier. No other actions or agreements relieve the supplier of the responsibility to provide parts, materials and services that are in conformance with Honda's purchase order or requirements.

Manual Control

This manual is the property of Honda. While the supplier has on-line access to this manual, downloaded or printed copies shall be kept in a secured and controlled manner. Copies of sections or individual pages are permitted for training or informational use, but shall be controlled to insure the most current version is in place. This manual contains confidential and proprietary information of Honda and may not be disclosed to any other person or entity without prior written consent of Honda.

Conformance to ISO 9001 ISO 14000 and ISO 26262

All suppliers to Honda shall conform to the requirements described by ISO9001 Standard. Unless otherwise notified by Honda, suppliers are encouraged, but not required, to have their conformance confirmed by an independent audit. Honda has the right to audit and assess a supplier's conformance to the ISO9001 Standard and the Quality Control Regulations regardless of the supplier's registration status. The above expectations also apply to ISO 14001. The above expectations also apply to ISO 26262 for suppliers providing safety-related systems that include one or more electrical and/or electronic system. Each supplier is responsible for obtaining any updates or revisions to the standards.


HSQM-0002 2/16 04/01/2019

Additional Requirements

Specific procedures, forms, timing and other requirements used by Honda and required of the supplier are detailed in this manual. The following items are in addition to the requirements of ISO. Document and Data Control - the supplier shall establish a procedure to

maintain all applicable drawings, specifications and quality control documents to the most current status. All obsolete information shall be removed from active use at the time it becomes obsolete (or otherwise marked as obsolete). Contents and date of changes shall be retained for a minimum of 20 years, unless Honda specifies a longer period.

Purchasing - The supplier shall enter into agreements with its respective

sub-suppliers and shall provide related terms of these quality control regulations, especially, but not limited to, change point control. If Honda deems it necessary to inspect any sub-supplier's quality system, production process or inspection procedures and records; Honda and/or the supplier shall be permitted access.

Lack of a laboratory facility or equipment does not exempt the supplier

from providing Honda with applicable test results. Honda retains the right to specify statistical techniques required for

establishing, controlling and verifying process capability and product characteristics.

Minimum Process Requirements includes all component parts and/or

materials (not solely Tier One). Minimum Quality Systems Requirements as detailed on the following

pages. Suppliers shall conform to these requirements beginning April 1, 2007.


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2.1.2 Corrective Action System

Corrective Action Flow / Process

Corrective action system requirements apply to both external parts problems and to internal problems. This includes, but is not limited to customer reported problems found in production facilities or in the market (issues that reached the final customer). Use of the system for internal problems may be dependent on achieving threshold triggers for quantity and/or severity.

Supplier’s process for corrective action shall be documented in flow chart form. It

shall identify: 1) Responsibility for investigation, approval, and review of the corrective action and its effectiveness; 2) Responsibility for revision of quality documents to reflect corrective and preventative actions; and 3) Responsibility for containment activity.

The corrective action process as described on the flow chart shall link to or direct the user to the supplier’s change point control system or otherwise trigger use of an IPPAAR or IPP where appropriate.

The flow chart shall trigger an examination of similar parts or processes that potentially may have the same or similar problems. Corrective action shall be extended to these same or similar parts or processes (horizontal application).

Corrective Action Management

Supplier is to maintain a written or electronic listing (log) of customer reported problems. The same or similar listing shall be used for internally found problems.

The log is to contain problem description, cause, corrective action, reply due date,

planned and actual implementation dates, and how effectiveness of the corrective action was confirmed before closure.

Using the listings or logs, open and closed issues shall be reviewed on a periodic basis

by senior management (at least monthly). Internal triggers should be established to assure minimum customer requirements for containment and closure speed are met.

The open issues report shall be presented to executive management a minimum of once

per month regarding issues causes, closure status, and time to closure. At a minimum of once per year, as part of the business planning cycle, an analysis of

customer complaints, reported problems, and significant internal issues shall be conducted. The analysis is to identify common threads and generate a plan that will reduce similar future complaints.

The listings of customer reported problems and significant internal issues shall be

utilized as a problem history for new model development and other changes (e.g. location change, outsource, etc).

Note: Supplier shall decide what is significant; e.g., issues that if they had escaped

would have resulted in an A rank trouble report and items exceeding a threshold for cost and/or hours to correct.


HSQM-0002 4/16 04/01/2019

2.1.3 Operation Standards, Training, and Process Job Qualification

Operation Standards

(Note: An operation standard is a documented description of how the job process shall be performed, process points of emphasis, and other information deemed relevant and necessary for the job process. The information may be in a single document or divided into appropriate portions in multiple documents. Operation Standards may also be known as ‘Work Instructions’, ‘Standard Operating Procedures (SOPs)’, and other similar names.)

An operation standard shall be created for each distinct job process or work station. Operation standards shall be controlled documents and on hand near the work covered

by the standard. Operation standards do not have to be on display at all times, but they shall be accessible by operators in seconds, not minutes.

Note: Studies have shown that people often forgo quality over easily accessible

information. The guideline, "accessible by operators in seconds, not minutes," is to help assure that the most authoritative information (i.e., the operation standard) is as accessible as asking a nearby coworker.

There shall be a documented system that describes how operation standards are

created, reviewed, approved, and revised. The system shall define how compliance with the control plan (PQCT) is maintained. Additionally, the system shall include an uncomplicated method with timely feedback for production operators to propose changes to operation standards.

Operation standards are to include: list of materials and components; description of

process steps and sequence; description of machine and tooling settings; any applicable lot control, first in-first out, or labeling requirements; and a designation of all points of emphasis (critical points) in the process. Emphasis points are to include failure modes if operation standard is not followed (i.e. why a process shall be done in a certain way).

Using appropriate language and visual aids, the operation standards shall be able to be

understood by a significant portion of the applicable workforce. For those not able to read and/or understand the operation standard, a documented alternative method shall be used to ensure understanding and compliance.

The operation standard shall include instructions on line or machine changeovers,

normal operator quality and equipment checks and maintenance reject triggers, and abnormal responses.

Any limit samples, master samples, or poka-yoke master samples used in the process

shall be referenced in the appropriate operation standard.


HSQM-0002 5/16 04/01/2019

2.1.3 Operation Standards, Training, and Process Job Qualification, Continued

Training and Process Job Qualification

There shall be a defined process and procedure by which individuals are trained and their qualification to perform the job process is evaluated.

Job process operation standards shall be a defined and integral part of the training and

qualification process. Qualification to perform a specific production job process shall be based on an

evaluation occurring after training that confirms the individual meets predetermined and objective criteria covering both the content of the job process and the ability to perform within the required cycle time.

Records of status of qualification to be kept close to the job process and shall be on

hand to determine both: 1) process jobs for which an individual is qualified and 2) individuals that are qualified to perform a given job process.

When the content of a job process changes, all individuals qualified for that process

shall be qualified for the change and records shall be revised upon completion of the change qualification.

In the event that an individual exceeds a predetermined period time without

performing a job process for which they are qualified, that individual’s qualification shall lapse and they shall be qualified again.

Qualification for a job process shall consider start up (equipment, poka-yoke checks,

etc), any repair or rework processes, any routine maintenance that is operator responsible, and detection and response to an abnormality in the process. Similar qualification for general quality systems shall be done including, but not limited to ‘Suspect and Nonconforming Parts’, ‘Change Point Control’, ‘First Piece Confirmation’ (if necessary), etc.

There shall be a defined procedure that is applicable whenever an individual that is

less than fully qualified is performing a job process. The procedure shall describe additional precautions (safeguards) that shall be taken, what data or information shall be collected and retained, and what approvals shall be obtained to assure quality of the product.

Difficult and/or critical job processes may be designated for only supplier employees

and less critical and/or easier to learn job processes normally performed by less experienced or contracted (‘temporary’) employees. However, the qualification requirements apply to all job processes and individuals regardless of whether they are supplier employees or contracted employees.


HSQM-0002 6/16 04/01/2019

2.1.4 Process Control

PFMEA (Process Failure Mode and Effects Analysis)

Note: See also HSQM-0018 “Process Failure Mode and Effect Analysis”

Suppliers are to create and maintain PFMEAs per HSQM-0018. Suppliers are required to have documented problem histories that provide one set of inputs into PFMEA creation. The supplier shall have a documented system that describes how PFMEAs are created, reviewed, approved, and revised. It is recommended the system description be in flow chart form. The system shall be linked to and triggered by the supplier’s Change Point Control system and the supplier’s Corrective Action system to ensure that the PFMEA accurately represents the most current process.

PQCT (Process Quality Control Table)

Note: See also HSQM-0021 “Process Quality Control Table”

Suppliers are to create and maintain PQCTs per HSQM-0021. The supplier shall have a documented system that describes how PQCTs are created, reviewed, approved and revised. A primary input into creation of the PQCT shall be the PFMEA (when required). It is recommended the system description be in flow chart form. The system shall be linked to and triggered by the supplier’s Change Point Control system and the supplier’s Corrective Action system to ensure that the PQCT accurately represents the most current process. The PQCT shall be used to input critical control items to the process operation standards.

Error-Proof and Inspection Devices (Poka-Yoke)

The function of each error-proof or inspection device (also known as poka-yoke) shall be confirmed periodically. The testing schedule shall be based upon the relative importance of the condition that the device checks. The confirmation frequency and method shall be documented on the PFMEA (if applicable), the PQCT, and the operation standard and/or the equipment check sheet.

Each such device shall be confirmed independently of other such devices. The

operation of such devices shall be confirmed both positive (device detects abnormality intended) and negative (does not alarm for non-abnormality).

Master parts (test shills) used for confirming error-proof and inspection devices shall

be controlled. They shall be approved by appropriate authority, uniquely identified and labeled for intended use, issued and stored in designated locations, and inspected periodically for damage or deterioration. A log shall be maintained of all such master parts.

Successful completion of an error-proof or inspection device confirmation shall be

recorded. A confirmation attempt that is unsuccessful shall trigger a response to be defined by the supplier’s policies regarding Suspect and Nonconforming Parts.

A confirmation attempt that fails initially, but is successful in multiple attempts

thereafter, shall still be considered a failure unless and until the situation is reviewed by appropriate authority.


HSQM-0002 7/16 04/01/2019

2.1.4 Process Control, Continued

Data Collection

Suppliers are to continuously collect data from each production process. Such data is to include number of parts produced and number and types of defects. The amount and causes of downtime are also to be collected. Additionally, any machine or process adjustment made during production shall be logged and stored close to the process or equipment. (If an adjustment must be made outside what is permitted in the PQCT, it shall be treated as an abnormal process. See Section 8.4, Abnormal Process.) The quality related data shall be used:

1) To establish short term trigger points to indicate process problems (and requiring

analysis and corrective action) and

2) For longer term analysis to establish improvement strategies. Such data shall be available to Honda representatives upon request.

First Piece Confirma-tion and Retain

Note: Provisions of ‘First Piece Confirmation and Retain’ do not apply to parts produced with individual serial numbers for which production parameter data and quality confirmation data, linked to the serial number, is collected and retained.

Suppliers shall have a documented system whereby the first production part after any

equipment changeover, tooling or fixture change, shift or other personnel change, etc. is reviewed and approved.

For Plastic or Rubber Molding (including injection and extrusion), Machining, and

Casting, the first approved part from each discrete production run shall be identified and retained. At a minimum, the part shall be retained until an approved part is produced on the next subsequent production run.

For Stamping, the last piece from each discrete production run shall be identified and

retained. At a minimum the part shall be retained until an approved part is produced on the next subsequent production run.

Process and Equipment Check Sheets

Detailed check sheets shall be created and implemented for recording of equipment parameters and verification of process controls (including alarms, preset wrenches, poka-yokes, etc.). Check sheets shall be completed at the beginning of each shift and after any process change including maintenance, or as described in the PQCT.

All operator checks shall be recorded. Where possible, entries to the records should be

quantifiable (e.g. actual numbers) rather than ‘ok’ or a ‘checkmark’. Any time data is found to be outside specified requirements, there shall be evidence

the condition was recognized and a clear record of what action(s) was (were) taken.


HSQM-0002 8/16 04/01/2019

2.1.5 Change Point Control

Change Point Control

The supplier shall have a documented change point control system, summarized in flowchart form, to receive, review, and approve or reject change points. The suppliers system shall link to and trigger the use of Honda’s change point control, IPPAAR, and IPP requirements. These requirements include, but are not limited to: a clear description as to what type of change requires approval; and a formal review and approval process.

Change in Part or Process from Sub-Supplier

Honda’s change point control requirements shall be passed to lower tier suppliers (sub-suppliers) as requirements from the supplier to the tier 2. The supplier shall have a documented system, summarized in flowchart form, to receive, review, and approve or reject change points from sub-suppliers. The system shall trigger use of Honda’s IPPAAR and IPP system when required. These requirements include, but are not limited to: a clear description as to what type of change requires approval, a formal review and approval process, a system for the sub-supplier to submit to the supplier proposed or anticipated changes, and a method of clearly identifying the initial shipment of parts to which the change applies.

Change in Supplier’s Manufacturing Conditions

The supplier shall have a documented system, summarized in flow chart form, to propose, review, and approve or reject changes in the suppliers own manufacturing conditions. The system shall trigger use of Honda’s IPPAAR and IPP system when required. Manufacturing conditions is a general term used to describe Types of Changes No. 3 through No. 10 in HSQM-0041, “Change Point Control”. These changes are: Material Change, Manufacturing Method Change, Process Order Change, Machine Change, Jig/Tool Change, Die/Mold Change, Inspection Method Change, and Transportation/Packaging Change.

Change in Source of Materials or Components

The supplier shall have a documented system, summarized in flow chart form, to propose, review, and approve or reject changes in the source of materials or component parts. The system shall trigger use of Honda’s IPPAAR and IPP system when required.

Record Keeping and Traceability

The supplier shall maintain records of all proposed change points submitted to their change point control system. Records shall include, description of change, approval level required (internal only or customer approval), approval status (including reference numbers), initial production part lot numbers and shipping data.


HSQM-0002 9/16 04/01/2019

2.1.6 Supplier Management

Supplier Quality Management

Responsibility within the supplier organization for sub-supplier quality shall be defined.

A quality manual, detailing the supplier’s requirements, shall be issued to sub-suppliers. The media used for the manual (paper or electronic) is of supplier’s choice.

Supplier shall pass Honda requirements for control of new-model and mass-production

quality to all sub suppliers, including but not limited to requirements for New Model Launch, Change Point Control, Minimum Process Requirements, Lot Control and Traceability, and Corrective Action.

Supplier performance measurement system shall be defined with targets issued

periodically to all suppliers, feedback of results to suppliers at least monthly, and defined activity for suppliers that consistently do not achieve their target.

Component Part and Material Quality Assurance

When adding new suppliers for new model or any other reason, supplier visits shall be made by qualified personnel to assess the suitability of potential suppliers to become approved sub-suppliers.

The type and frequency of any receiving inspection, sampling plans, and sampling

audits shall be based on component part or material problem history and potential impact.

There shall be a defined system to report problems with component parts and materials to suppliers. The system shall include a reporting method, reply method, status tracking and reporting mechanism, and reply approval method including confirmation of countermeasure effectiveness.

Supplier visits shall be made by qualified personnel to confirm cause and corrective

action for significant problems. Supplier visits shall be made by qualified personnel to confirm significant new model and change point issues. Visits are also to be made to examine the supplier’s production process and quality system against predetermined criteria. Frequency of these visits to be determined based on impact of supplier’s problems and supplier’s overall performance.


HSQM-0002 10/16 04/01/2019

2.1.7 Lot Control and Traceability

(Note: For additional requirements see Honda Supplier Quality Manual HSQM-0028

“Traceability and Lot Control”)

Lot Control Suppliers are to manufacture parts for Honda in discrete and identifiable groups. A

group of parts produced under the same circumstances and during a finite period of time is called a ‘lot’. Each lot shall be identified with a unique lot number or code.

A new lot shall be formed when:

1) A new production shift begins. 2) A line, machine, or area ends the production of one part number and begins

another. 3) There is a change in manufacturing method, equipment parameters, or inspection

method. 4) For associate assignment, material lot, or component part lot changes when

required by the PQCT or LNDD specifications. When a supplier has multiple production processes (for example casting, machining,

and assembly), the supplier shall: 1) Treat each process as a discrete entity and record incoming parts or material lot

numbers and assign lot numbers to parts leaving the process.

or 2) Keep the lot configuration from the initial process (e.g. casting lot) intact

throughout the remaining manufacturing processes.

The number of parts in a lot may vary from a single part to a maximum of one shift’s worth of production.

Key aspects of lot formation and control shall be reflected to the process control documentation where appropriate (e.g. FMEA, PQCT, operation standards).


HSQM-0002 11/16 04/01/2019

2.1.7 Lot Control and Traceability, Continued

Traceability The manufacturing conditions and component part and material lot numbers shall be

recorded for each manufacturing lot. The supplier shall maintain FIFO (First in, first out) usage of component parts and

materials, work in process (WIP), and shipping of finished goods. FIFO usage of WIP includes both WIP between processes (e.g. between injection molding and painting or sent out to a sub-supplier to be plated, heat treated, painted, etc.) as well as WIP within a process (e.g. between stations on an assembly line).

Product removed from the normal process flow (e.g. rework or repair) shall maintain

traceability. The traceability shall include both component parts and materials tracking.

Records of repair or rework performed and identification of any component parts used

in the repair shall be maintained. Suppliers are to ensure that provisions of these lot control and traceability

requirements are required of all sub-suppliers, including subsidiaries, parent companies, overseas affiliates, etc.


HSQM-0002 12/16 04/01/2019

2.1.8 Inspection, Test and Calibration

Inspection and Tests

Note: Part confirmation and specification tests refers to tests performed by the quality department or others done on a periodic but infrequent basis and often requiring specialized equipment or an extended period of time. Examples include dimensional layouts, burn resistance tests, and annual photometric testing. Frequent, in process quality checks are not subject to requirements of this section.

All periodic part confirmation or specification tests shall be listed on a master

schedule. This consolidated schedule reflects all requirements that may be listed on the drawing or in Honda Engineering Specifications, on PQCTs, in Honda Process Inspection Standards, or elsewhere. The results of periodic part confirmation or specification tests shall be reported to executive management on a periodic basis.

The supplier shall have a documented procedure describing actions to be taken should

any part confirmation or specification test fail. This procedure shall link to or trigger the suppliers “Suspect and Nonconforming Parts” procedure(s).

Calibration Where applicable, the supplier shall periodically assure the continuing acceptability of

master samples, inspection and error-proof device test samples, and process jigs and fixtures. The supplier shall maintain a list of such samples and process items requiring confirmation and a schedule for confirmation. (Also see 3.3.3). Responsibility for confirmation shall be documented and a report of confirmation results issued to executive management on a periodic basis.

Suppliers shall have a documented gauge Repeatability and Reproducibility program

for all tools, inspection devices, and check fixtures used for applicable measurements (e.g. critical measurements or those designated by Honda).


HSQM-0002 13/16 04/01/2019

2.1.9 Suspect and Nonconforming Part and Abnormal Process

Suspect and Nonconforming Parts

The supplier shall have a documented procedure(s) describing how suspect and nonconforming components and materials, work in process, and finished product are handled. The procedure shall include how such goods are identified (tags, ‘red bins’, etc.), how such goods are isolated from similar goods whose status is not suspect or nonconforming, how disposition is determined for such goods, and triggers to escalate the disposition process. Roles and responsibilities shall be clearly identified.

The supplier shall create and maintain a listing (‘log’) of goods whose status is suspect

or nonconforming and the disposition of such goods. A report shall be issued to executive management on a periodic basis describing such goods and the status of the disposition determination.

The supplier shall have a documented procedure describing how to handle and

determine the disposition of dropped parts. Dropped parts shall be identified as nonconforming parts until application of the dropped parts disposition procedure.

Processes whose PFMEA severity is 9 or 10 must have a separate process flow for

how to make a proper judgment and disposition of nonconforming or suspect nonconforming parts. A generic procedure that applies to all processes regardless of severity shall not be used.

For critical items that have been judged NG “no good” by the equipment and

cannot be confirmed by human via nondestructive means, the supplier shall not allow the NG status to be changed or over-ridden by human judgment.

Routine Repairs or Rework

(Note: Routine repairs and routine rework refer to parts or work in process that are discovered to be nonconforming during the production process or inspection and the nonconformance is frequent enough that a method, location, and manpower for repair or rework of the defect is planned in advance. It does not apply to operations (such as trimming flash) that shall be done to 100% of product – these are treated as a normal job process.)

Production processes requiring routine repairs or rework shall be identified by the supplier. Repair or rework operations shall be treated as standard job processes and, as such, are subject to requirements for PQCT, FMEA, operation standards, and job process qualification.

The quantity of repairs or reworks performed and the specific nonconformance

corrected shall be recorded for each lot of parts produced. The data shall be used to devise improvement strategies.

Parts that have been repaired or reworked shall be marked as to differentiate them

from parts that were not repaired or reworked. Such marking shall be approved by all appropriate Honda Parts Quality Departments and described in the PQCT and operation standards. In individual cases, the Honda Part Quality Department may elect to waive the marking requirement if the marking may cause additional quality or manufacturing issues.


HSQM-0002 14/16 04/01/2019

8.2.4 For routine repair or rework parts, the supplier shall request and adhere to Honda’s direction for lot control and traceability requirements.

8.2.5 Product removed from the normal process flow (e.g. rework or repair) shall, where

applicable, be reintroduced to the normal flow at the point at which they were removed. For parts repaired after the normal flow is completed, such parts shall pass all inspection steps included in the normal flow (e.g. shall go through QA machine after repair).

Non-routine or Special Repairs

(Note: Non-routine or special repairs refer to modifications or adjustments made to parts or work in process in response to a temporary abnormality. It also refers to adjustments or modifications made to parts as a result of a customer request to change or modify a specification.)

The supplier shall have a documented procedure to describe the handling of non-routine and special repairs and rework. The procedure shall describe roles and responsibilities, including authority for approval of the repair or rework process and technique. The procedure shall link to or refer to the suppliers change point control requirements and Honda’s IPPAAR/IPP requirements.

For each special repair or rework, the supplier shall create specific work instructions

or operation standards describing the work to be done. Only associates qualified to the operation standards shall be permitted to perform the special repair or rework.

For each special repair or rework, the supplier shall request and adhere to Honda’s

direction for lot control and traceability requirements. Product removed from the normal process flow (e.g. rework or repair) shall, where

applicable, be reintroduced to the normal flow at the point at which they were removed. For parts repaired after the normal flow is completed, such parts shall pass all inspection steps included in the normal flow (e.g. shall go through QA machine after repair).

Abnormal Process

(Note: An abnormal process is a production process, step, or operation that temporarily and knowingly varies from that described by the PQCT and/or operation standard.)

The supplier shall have a documented procedure describing necessary notifications, approvals, and safeguards required each time an abnormal process is used. The procedure shall link to or refer to the suppliers change point control requirements and Honda’s IPPAAR/IPP requirements. The procedure shall describe roles and responsibilities, including authority for approval of the abnormal process, the authority for approval of quality safeguards, and the authority for evaluating any potential impact to capacity and delivery.

For each instance when an abnormal process is employed, the supplier shall create

specific work instructions or operation standards describing the work to be done. These may be a revision of the normal operation standards or additional or supplemental standards. Only associates qualified to the operation standards shall be permitted to perform the abnormal process.


HSQM-0002 15/16 04/01/2019

2.1.10 Organization

Roles and Responsibilities

The supplier shall identify and document roles and responsibilities for each division, department, or other group within the organization.

Quality Planning

The supplier shall, on periodic basis not less than annually, analyze internal and external part nonconformities, audit results, and other quality related issues, identify production processes and/or quality systems that are deficient, and create a plan to improve those processes and/or systems. Plans shall include appropriate numeric targets. Progress relative to the plan shall be reported to senior and executive management on a periodic basis. Responsibility for this activity shall be included in the organization’s role and responsibility description.

2.1.11 Quality Systems and Policies

Quality Systems and Policies

The supplier shall establish and document general policies and procedures applicable to all relevant processes. Such general policies and procedures include, but are not limited to, the following: -Use of materials, components, work in process, and finished goods in a ‘first in, first out’ manner. -Operation of production processes in a ‘one piece flow’ manner. - Handling of dropped parts (see 8.1.3). - Handling of parts found outside normal areas. - Control of line changeover from one product to a different product. -Completion of work at each production process or station prior to leaving the station for break, lunch, end of shift, or other reason.

The supplier shall establish a standard formal problem solving method (e.g. 5P, 8D, etc.) to be used when safety, quality, warranty, and delivery problems occur. Threshold levels may be established to trigger use of the problem solving tool. A standard review process by management shall be established.

All relevant personnel shall be trained and qualified for these general policies and the selected problem solving method in a similar manner to specific job process training (see 2.0 Operation Standards, Training, and Process Qualification).

The supplier shall develop and implement quality metrics to manage and control quality performance at the plant, departmental, and production line levels. Minimum quality metrics shall include:

- First pass rate (or fraction or percent defective) - Escaping defect rate


HSQM-0002 16/16 04/01/2019

2.1.12 Preventive Maintenance

Preventive Maintenance

Suppliers are to have a documented schedule for periodic maintenance required for all production process equipment and fixtures. At a minimum, PM schedule shall be based on equipment manufacturer recommendations and past problem history. Predictive maintenance programs may also be used. Where possible, the schedule shall be based upon running time or machine cycles rather than calendar time.

Results of scheduled maintenance activity shall be reported to executive management

on a periodic basis including maintenance not performed as scheduled. Each critical production process equipment or specialized fixture shall have an

individual history specific to the equipment or fixture. This equipment history shall be used by both maintenance and production to record all problems, adjustments, repairs, and checks of. This history shall be analyzed and used for future improvements, budgeting, and for adjusting preventive maintenance frequencies.

Upon completion of any adjustment, modification, repair, or preventive maintenance

(whether by maintenance, engineering, production, or any other department or outside service provider), a quality confirmation system shall be in place to assure and record the quality of the product. The system shall include linkage to the supplier’s change point control system and, when required, linkage to Honda’s IPP and IPPAAR requirements.

If any check, calibration, or periodic maintenance finds the equipment or fixture to be

outside of specified requirements, all parts produced since the last previous acceptable check, calibration, or periodic maintenance shall be considered ‘suspect’ and handled per the suppliers policy regarding ‘suspect and non-conforming parts’.

All maintenance activities, including daily operator equipment checks and poka-yoke

confirmations, shall be recorded. Where possible, entries to the records should be quantifiable (e.g. actual numbers) rather than ‘ok’ or a ‘checkmark’.

Adjustments, calibrations, repairs, and checks of equipment and fixtures are only to be

performed by qualified personnel.

Minimum Process Requirements

HSQM-0060 Page 1/4 04/01/19

Purpose The purpose of this document is to clarify and communicate minimum process requirements to reduce process related defects.

Scope This procedure applies to all OEM purchased parts and material products

shipped to North American Honda plants. This also includes any component parts shipped to a Tier 1 supplier. This procedure applies to the processes listed below:

Casting Error Proofing Fluid Fill Heat Treatment Hot Plate Welding Molding Label Machining Painting Part Marking PCB Sonic/ Vibration/ Friction Welding Stamping Torque Weld Wire Harness and Electrical Connection Leak Test Traceability

Minimum Process Requirements Definition

The Minimum Process Requirements define the minimum controls and methods Honda requires in applicable manufacturing processes. These requirements were established to prevent future process related quality defects. These requirements are minimum process requirements. PQ may require additional process requirements where applicable (e.g. Process Inspection Standard).


HSQM-0060 Page 2/4 04/01/19

NM Flow

Initial Quote The supplier must assure the Minimum Process Requirements are built into the

applicable processes. Requirements must be included when developing each manufacturing process and reflected in the PQCT. The supplier must complete the Minimum Process Checksheet. The quote must include meeting the minimum process requirements as stated in this procedure. NACP is responsible for requesting quotes per drawing specifications. At that time, NACP communicates through the RFQ that the supplier must quote based on meeting the Minimum Process Requirements. If a supplier cannot or will not meet the minimum process requirements, the supplier is required to respond in writing explaining the requirement that they are unable to meet and the reason. This correspondence must be sent to NACP with the part quote. NACP forwards the supplier’s response to PQ. NACP, PQ and the supplier attempt to resolve the issue. If no agreement can be made, the issue is escalated to upper management. The quote may be considered a supplier no quote. Note – If a supplier cannot or will not meet the minimum process requirements, the supplier is required to present how it will guarantee quality.

MPRs Issued via Supplier Quality Manual

RFQ Issued - MPR Requirement Noted

New Model Supplier Kick Off

Packet

Confirm Plan to Meet MPRs

Submit PFMEA /PQCT

Check Compliance with MPRs

Audit Processto PQCT

MPR Process Confirmation Checksheet

NMR 3 / PA-3 NMR 4,5 / PA-4/PA-5

MPR Explanation Letter Mailed to

Suppliers

NA SQD Issued CPG IssuedPH Operations

NMS PH NMS

Supplier PH NMS

PH NMS

Revise

NMR 2 / PA-2


HSQM-0060 Page 3/4 04/01/19

NMR3 / PA-3 Evaluation

Suppliers are responsible to confirm the Minimum Process Requirements are included in the PQCT before submission to PQ for review. If a supplier cannot or will not meet the minimum process requirements, the supplier communicates concerns to PQ. PQ and the supplier attempt to resolve the issue. If no agreement can be made, the issue is escalated to upper management and NACP is contacted. The supplier is responsible to develop their manufacturing process, incorporating the minimum process controls. Note – the applicable Minimum Process Requirements are included in the PQCT development.

NMR 5 / PA-5 Evaluation

At PQ management’s discretion, PQ project members will audit the supplier’s processes to confirm conformance to the PQCT. Any deviations must be addressed immediately. PQ will document concerns on a QAV report when applicable. Suppliers are responsible to maintain adherence to all applicable minimum process requirements during process development and revisions to the PQCT. The MPR Checksheet is used as a tool for confirmation that the minimum process requirements were verified when developing the supplier’s manufacturing process. The check sheets can be found on the Honda website in the Supplier Quality Manual. The website is “www.HondaWeb.com.” If a supplier does not adhere to the minimum process requirements, PQ communicates concerns to the supplier. PQ and the supplier attempt to resolve the issue. If no agreement can be made, the issue is escalated to upper management and NACP is contacted. PQ notifies NA SQD of the supplier’s failure to conform to the minimum process requirements. Failure to comply may result in a supplier class change.


HSQM-0060 Page 4/4 04/01/19

Mass Production

At PQ Management’s discretion, PQ audits the supplier’s processes to confirm conformance to the minimum process requirements. Any deviations found must be addressed immediately. PQ will document concerns on a QAV report when applicable. In the event of a design change to the part, that would impact a MPR requirement, the IPPAAR process must be followed to ensure MPRs are incorporated. They must also be applied when the supplier has a part issue that the MPR will countermeasure. It is the supplier’s responsibility to maintain the Minimum Process Requirements.

China Compulsory Certification (CCC)

HSQM-0120 Page 1/13 02/01/2013

Purpose To clarify the specific Honda requirements that must be met for parts that have CCC requirements.

Responsibility At the beginning of each new model, NM Purchasing is responsible to communicate the CCC required part list to the impacted suppliers and the timing for when CCC approval must be obtained and markings applied to the parts.

The supplier is responsible to ensure parts meet the China Regulation requirements by the required project dates and must provide copies of all required documents to Honda.

NM Purchasing is responsible to track all supplier CCC certification activities.

During mass production, the supplier is responsible to inform purchasing of any changes to CCC parts in advance of the change with time consideration to allow for part and vehicle certification updates.

MP Purchasing is responsible to approve any changepoints that would affect CCC parts through the IPPAAR process.

Scope This document applies to all parts that require CCC marking per the China Government Regulations.


HSQM-0120 Page 2/13 02/01/2013

Determining CCC Requirement:

Vehicle Products CCC Implementation Rules*

GB National Standard*

Safety Belt CNCA-02C-026 GB14166 / GB8410 Tire CN CA-03C-027 GB9743 Glass CN CA-04C-028 GB9656 Horn CN CA-02C-055 GB15742 Reflector CN CA-02C-056 GB11564 Brake Hose CNCA-02C-057 GB16897 Exterior Lights & Lamp Signal Device

CNCA-02C-058

Head Lamp (Filament Lamp) GB4599Head Lamp (Discharge Lamp) GB21259Front Fog Lamp GB4660Rear Fog Lamp GB11554Brake Lamp GB5920Reversing Lamp GB15235Turn Lamp GB17509Parking Lamp GB18409Side Marker Lamp GB18099

Rear-view Mirror CNCA-02C-059 GB15084 Interior Parts CNCA-02C-060 GB8410 Door Lock & Door Hinge CNCA-02C-061 GB15086 Fuel Tank CNCA-02C-062 GB18296 Seat & Headrest CNCA-02C-063 GB9743

*Note: Listed is the general parts list and applicable rules and standard numbers and should be used as a guideline only. Please reference latest China Regulations for all the latest requirements.


HSQM-0120 Page 3/13 02/01/2013

Pur

chas

ing

(Pla

nt-s

ide Q

ualit

y)

Sup

plie

r D

raw

ings

P

roje

ct

6

New Model CCC Process Flow

D-1 Flow:

Following are two New Model Development flows – “D-1” Project flow and “No Prototype Development” (NPD) Flow:

Timing*

n-30 n-28 n-26 n-24 n-22 n-20

n-18 n-16 n-14 n-12 n-10 n-8

n-6 n-4 n-2 n n+2

CCC Kic k -off Meeting 1 DAN QC RC MP

China

(KH)MP

Planning Dwg D1-1Dwg

D1-2 Dwg

FPD MPD Drawing update

3C Note: Mus t be on drawing Part ID: If av ailable Fac tory ID: If availabl e

3C Note: Mus t be on drawing Part ID: Mus t be on drawing Fac tory ID: If available

(Any new c hanges requi re CRFs ).

5 China Obtai n CCC Certific ation

8 - China Part Approv al Certificate

Submit

China Application Draft Submis sion

Applic ation Submi s s ion Ti res , Seatbelts, Glas s

- Permis s ion to Print Approval - Fac tory Audit Report

8

Supplier s ubmits Part Ty pe ID rel ated CRF

2 Part Ty pe ID Logic s heet to Honda Purc hasing

All ex c ept Tires , Seatbelts, Glass

Obtain CCC Certific ation - China Part Approv al Certificate - Permis s ion to Print Approval - Fac tory Audit Report

when needed

Submit part approv al s c hedule

7

CCC Certific ation mark ings appli ed to parts

CCC Certific ation mark ings applied to parts

3 4

Prov i de D1-1 Dwg feedbac k to Honda Purc has ing

Prov ide D1-2 Dwg feedbac k to Honda Purc has i ng

10 10

Collec t and prov ide feedbac k to s uppl iers

Honda Purc hasing reques ts s upplier to get approv al bas ed on dwg and Cert reqt timing

Collec t and prov ide feedbac k to s uppliers

9

CCC Certific ation Documents - Coll ec t and provide feedbac k to s uppliers

9

CCC Certific ation Documents - Collec t and provide feedbac k to s uppliers

Honda Purc has ing confirms need and/or pres enc e of Part Ty pe

ID/Logic Sheet

Normal CRF proc es s

* Note: Timing shown in months where 'n' is mass production start for China market (KH) vehicles.


HSQM-0120 Page 4/13 02/01/2013

Pur

chas

ing

(Pla

nt-s

ide Q

ualit

y)

Sup

plie

r D

raw

ings

P

roje

ct

No Prototype Development (NPD Flow): Timing* n-30 n-28 n-26 n-24 n-22 n-20 n-18 n-16 n-14 n-12 n-10 n-8 n-6 n-4 n-2 n n+2

CCC Ki c k -off Meeting 1 DAN-0 DAN QC RC MP

China

(KH) MP

Planni ng Dwg Final Planning Dwg Die Go Dwg Mas s Production Dwg Drawing update

3C Note: Mus t be on drawing Part ID: If av ailable Fac tory ID: If available

3C Note: Mus t be on drawing Part ID: Mus t be on drawing Fac tory ID: If available

5 China 6 Obtai n CCC Certific ation

8 - China Part Approv al Certificate

Submit

2 Part Ty pe ID

Chi na Application Draft Submis sion

Applic ation Submi s s ion Tires , Seatbelts, Glas s

- Permis s i on to Print Approval - Fac tory Audit Report

8

Supplier s ubmits Part Ty pe ID related CRF when needed

Logi c s heet to Honda Purc hasing All ex c ept Tires , Seatbelts, Glass

Obtain CCC Certi fic ati on - China Part Approv al Certificate - Permi s s ion to Print Approval - Fac tory Audit Report

Submit part approv al schedule

CCC Certific ation mark ings applied to parts

CCC Certific ation mark i ngs applied to parts

3

Prov ide Final Planning Dwg feedbac k to Honda Purc has ing

7 4

Prov ide Die Go Dwg feedbac k to Honda Purc has i ng

10 10

Collec t and prov i de feedbac k to s uppliers

Honda Purc hasing reques ts s upplier to get approv al bas ed on dwg and Cert reqt timing

Coll ec t and prov ide feedbac k to s uppliers

9 CCC Certific ation Documents - Collec t and provide feedbac k to s uppli ers

9 CCC Certifi c ation Documents - Collec t and provide feedbac k to s uppliers

Honda Purc has ing confirms need and/or pres enc e of Part Ty pe ID/Logic Sheet

Normal CRF proc es s

* Note: Timing shown in months where 'n' is mass production start for China market (KH) vehicles.


HSQM-0120 Page 5/13 02/01/2013

New Model CCC Process Flow (cont’d)

Below are explained the major steps of the CCC process flow:

Step

Major Step Details

Responsibility

1

CCC Kick-off meeting

- Issue CCC parts list to suppliers of parts that require certification. - Issue project CCC schedule to suppliers which outlines requirements for: overall project, certificate timing and applying certification markings to parts.

Honda Purchasing

2

Part Type ID

- Supplier submits Part Type ID Logic sheet to Honda Purchasing - Honda Purchasing provides supplier with approved Part Type ID logic sheet

Supplier/Honda

Purchasing

3

D1-1/Final Planning Drawing feedback

- Supplier reviews D1-1/Final Planning drawings and confirms with Honda Purchasing whether they have concerns with the CCC related details (i.e. GB standard, CNCA rules, etc.) on the drawing

Supplier

4

CCC Part Approval Schedule - Supplier must submit a schedule detailing CCC approval activity.

Supplier

5

China Application Draft Submssion

- Supplier submits draft part application to Honda Purchasing for review - Honda provides confirmation of application content

Supplier/Honda

Purchasing

6

China Application Submission - Supplier submits application for part approval to Chinese authorities

Supplier

7

D1-2/Die Go Drawing feedback

- Supplier reviews D1-2/Die Go drawings and confirms with Honda Purchasing whether they have concerns with the CCC related details (i.e. GB specs, CNCA, specs, CCC mark location, Part Type ID, CCC Factory Code, etc.) on the drawing

Supplier

8

Obtain CCC Certification

- Supplier must obtain the required certification/certificates. This step may also include part type testing and/or a factory audit.

Supplier

9

CCC Certification documents

- Submit to Honda Purchasing copies of: 1) Factory Inspection Report – A

copy of the supplier’s most recent Factory Inspection Report (initial or follow up).

2) China Compulsory Certificate (CCC Certificate) - A copy of the supplier’s CCC Certificate for the CCC part(s).

3) Permission of Printing/ Impressing Certificate – A copy of supplier’s Permission to Print certificate, if applicable. (Not applicable if supplier purchases CCC labels from China to apply to the part(s)).

Supplier

10

CCC Certification Markings

- Supplier makes required updates to ensure required CCC certification markings are present on the parts

Supplier


HSQM-0120 Page 6/13 02/01/2013

Required CCC Documents

Supplier shall submit the required China Compulsory Certification documents, as well as Honda required documents, to each plant’s CCC PIC. Supplier is required to ensure that the most recent revision of each document is sent to Honda.

CCC Part Approval Schedule

Honda shall request submission of a plan for obtaining CCC Certification.

Schedule Requirements and Timing

Exact submittal timing is project dependent. Requirements are given to suppliers as early as possible. The table below shows the basic approval steps that should be captured in the suppliers plan and the related submission requirements. Detailed plan requirements to be established between Honda plant and supplier. The timings listed below are for reference only.

O = Required U = Upon Request

STEP REQUIREMENTS PLAN SUBMISSION GENERAL TIMING

1 Complete Internal Type Testing U --- ---

2 Submit draft Part Approval Certificate Application to Honda for review O Copy of draft

application

~ n‐15 months

3 Submit Part Approval Certificate Application to CCC agency O ---

---

4 Prepare sample test parts U --- --- 5 Send sample parts to CCC agency O --- ---

6

Type Testing performed by CCC agency U ---

---

7 Receive Type Testing Report U Copy of test report --- 8 Factory Audit Scheduled O --- --- 9 Complete Factory Audit U --- ---

10

Receive Factory Audit Report

O

Copy of report

Tires, Seatbelts Glass:

Prior to DAN event

Other: Prior to QC Event

11 Receive invoice for certification costs U --- --- 12 Pay invoice for certification costs U --- ---

13

Receive Part Approval Certificate

O

Copy of certificate


Prior to DAN event

Other: Prior to QC Event

14

Submit application for Permission of Printing Certificate U

Copy of application

‐‐‐

Submit application for CCC Mark labels

15 Receive and pay invoice for Permission of Printing Certificate U ---

---

16

Receive Permission of Printing Certificate O

Copy of certificate


Prior to DAN event

Other: Prior to QC EventReceive CCC Mark Labels 17 Implement CCC Mark (tool, sticker, etc) U --- --- 18 Confirm CCC Mark on Parts U --- --- 19 Start Mass Production U --- ---


HSQM-0120 Page 7/13 02/01/2013

New Model CCC Parts Approval Flow (Supplier Activity)

Complete internal part type testing

Submit initial

Supplier receives design change and drawing for CCC part

Prepare for

Receive invoice for

Submit application for Permission of Printing certificate

Receive invoice certificate cost

application to CCC agency

Factory inspection certification costs Pay invoice for certificate cost

Prepare to send samples

Send Part Samples to CCC agency

Part Approval Test by CCC agency

Part passes type testing – receive

report

Factory inspection conducted

Pass inspection and receive Factory Inspection report

Factory ID is

issued

Pay invoice for certification costs Receive CCC Part

Approval Certificate

Parts Approval Certificate

Permission of Printing Certificate

Receive Permission

of Printing certificate

Submit application for purchase of CCC standard labels

Receive CCC labels

Apply CCC mark to

parts

Note: Process flow shown is a general outline; steps and sequence may vary depending on Chinese certifying agency being used.


HSQM-0120 Page 8/13 02/01/2013

Part Type ID Part Type IDs are identification numbers to identify products. They are noted on application docs, Part Certificates, and production parts.

Part Type IDs will be used to show that the part being sold in China is the same as the part that was approved by the China Government as shown on the Part Certificate.

Part Type ID is used to ensure conformity across each stage of the CCC process: application documents, shipment, sales and customs clearance.


HSQM-0120 Page 9/13 02/01/2013

Part Type ID (continued)

The Part Type ID consists of an X, Y, and Z component.

X: the Certification spec. code ‐ excludes

factory elements from certification

classification defined by parts under the

CCC Implementation Rules.

Y: Factory code ‐ corresponds to factory

ID which is received after passing factory

inspection.

Z: Option code (Optional) ‐ used for

classifying into multiple spec when

certification unit code is same and it is

hard to control

Any letter or number can be set to X, Y & Z. But setting must be shared with parts & vehicle manufacturers.

Example of an XYZ Part Type ID


HSQM-0120 Page 10/13 02/01/2013

Part Type ID (continued)

Once the supplier sets their Part Type ID, it needs to be approved by Japan Cert. The supplier completes a Part Type ID Worksheet and Part Type ID Logic sheet that explains what each character or their Part Type ID represents. The completed sheets are submitted to the Honda Plant and who then submits it to Japan Cert for approval. Once Japan cert approves of the Part Type ID Logic sheet, the Honda Plant will provide the supplier with an approved copy. If the Part Type ID requires to be changed/updated after the Final Prototype drawing is released, the supplier will require to submit a CRF to have the Part Type ID modified.

Part Type ID Logic Sheet Part Type ID Worksheet


HSQM-0120 Page 11/13 02/01/2013

CCC / Part Type ID Markings

Any part requiring a CCC mark is considered a government regulation part. The timing of the initial addition of the CCC mark and Part Type ID (if required) to the actual parts should be coordinated and agreed upon with Honda prior to applying the markings. It is important that the marking application timing coordinates with the vehicle certification timing. For the three commodities of Tires, Glass and Seatbelts, these parts require to have the markings applied by DAN event. Any issues found regarding the mark (missing mark, incorrect mark, etc) is considered a regulation violation and will be documented as an “A” rank severity issue. Suppliers should consider the CCC mark as a critical control point, and should follow previously established guidelines (i.e. Part Marking, Error Proofing MPR) and PAC-Vs (if required).

CCC CRFs CRFs will need to be generated by the supplier for the following CCC drawing related changes (but not limited to): • Plant ID due to mfg. location change • Part Type ID • Part marking location/method change • CNCA Rule or GB Standard update • Any changes that affect CCC certification/regulations CRF submission is to follow the normal CRF flow indicated in the SQM.

CRF submission timing must be in advance to changes to allow for the following time considerations: • CRF approval • Drawing issuance • Part re-certification (including testing if required) • Factory approval (active CCC or new) • Honda vehicle certification update For MP related changes CRFs should be submitted to initiate the change approval process. The CRF is submitted to the affected plant quality representative. IPPAAR flow will be followed pending the CRF approval to give the part change implementation approval.


HSQM-0120 Page 12/13 02/01/2013

Certificate Renewal Timing

In mass production, the Supplier is responsible for ensuring each of their CCC documents are renewed prior to the expiration dates. The standard validity period for each document is:

CCC Part Approval Certificate : 5 years (from initial issuance)

Permission of Printing Certificate : 1 year (from date of issuance)

CCC Factory Audit : A factory audit must be conducted every calendar year.

The expectation is that the expiring certificate is renewed at least 5 weeks prior to expiry.

The CCC PIC at each factory may request a plan for renewing the expiring certificate(s).

Mass Production CCC Related Certificate Renewal Flow (Supplier Activity)

CCC Part Approval

Certificate

Permission of Printing

Certificate

Yearly Factory Audit

Submit application for renewal of CCC Part Approval Certificate

Submit application for renewal of Permission of Printing certificate

Apply for yearly factory audit

Prepare to

send samples

Receive invoice Receive confirmation of factory

audit from auditors

Send part samples Pay invoice Pass audit

Part Approval Test Receive renewed CCC mark

Permission of Printing certificate

Receive invoice

Pass approval test & receive reports

Permission of Printing Certificate

Pay invoice

Receive invoice Receive signed copy of Factory

Audit Report

Pay invoice

Receive renewed CCC Part Approval Certificate

Parts Approval Certificate

Factory Report

Note: Process flow shown is a general outline; steps and sequence may vary depending on Chinese certifying agency being used.


HSQM-0120 Page 13/13 02/01/2013

Confirmation of Certificate Validity

Supplier is responsible for ensuring the validity of their certificates with the Chinese certification authorities. Honda may request the supplier for confirmation of certificate validity periodically each calendar year.

CCC Certificate Updates

Prior to obtaining a new or updating any existing CCC related certificate, the supplier must consult with the affected Honda plant(s) to:

a) Ensure that Honda plant is aware of the change being made. b) Ensure that the applicable vehicle CCC certification is updated

accordingly. c) Ensure any other certification documents are updated accordingly.

The affected Honda plant(s) will advise the supplier on how to proceed with the certification update with regards to timing. Depending on the update, a drawing change may be required for which a CRF must be submitted. Listed below are some guidelines with regards the change point and which certification document update is required.

Change Item CCC Part ApprovalCertificate Update*

Permission of PrintingCertificate Update*

Factory Inspection*

Part ID change

Yes

No; unless new Part Approval Certificate is

issuedNo

CNCA Rule / GB Standard Change

Yes

No; unless new Part Approval Certificate is

issuedNo

Manufacturing

location change

Yes; if certificate manufacturing

address is listed on certificate

Yes; if CCC Factory Code changes

a) Yes; if it is not a CCC approved factory. b) No; if other wise.

Factory or Sub- supplier location

change

Yes; if Factory address is listed on certificate

Yes; if CCC Factory Code

changes

a) Yes; if it is not a CCC approved factory. b) No; if other wise.

* Note: The China auditing agency that has issued the certificate has the final judgement on whether a certificate update is required based on location change. Honda will make recommendations but cannot control what the China audit agency will recommend/approve.

Bar Code Standard

HSQM-0030 Page 1/6 4/01/2016

Application Honda defines bar code requirements for maintaining scanability of bar code content. Those requirements apply to all applications where a bar code is placed on a part or container and then scanned for traceability.

Responsibility The following table lists responsibilities related to the bar code standard.

Who Responsibility

Supplier Submit sample mass production bar code label, with each LNDD sheet prior to

mass production and/or according to Change Point Control procedures. This should also include ISO/ANSI print quality test results.

PQ

Ensure that each LNDD sheet is routed through the Honda department that scans the bar code for sign-off and approval on bar code quality.

Ensure that each DSPS LNDD sheet is routed through Tier 1 supplier, where applicable, for sign off and approval for bar code quality.

Issue bar code standard to suppliers Analyze sample bar code labels Support the analysis of bar code samples

IS Support the analysis of bar code samples

Definitions The table below list definitions related to the bar code standard

Term Application Definition

Wide:Narrow Ratio, N Linear

Z2

space wideaveragebar wideaverage

N

Where:

2

space narrow averagebar narrow average Z

Minimum Reflectance

Linear QR

Data Matrix

Ratio of Rmin to Rmax Rmin is the lowest reflectance value on the scan profile

while Rmax is the highest reflectance value of the scan profile.

For a bar code to pass the lowest reflectance value for at least one bar code must be less than or equal to half the highest reflectance value for a space.

Symbol Contrast

Linear QR

Data Matrix

The difference between Rmax and Rmin. Value difference between light and dark symbol elements

Edge Contrast Linear

QR Data Matrix

The smallest difference between a space and an adjoining valley.

Bar Code Standard

HSQM-0030 Page 2/6 4/01/2016

Definitions (continued)


Decodeability Linear

Bar Code Symbology for code 39 or 128 requires that each character be composed of 6 narrow bars and 3 wide bars.

Bar Code Symbology for code 128 consists of a quiet zone, start/stop character, encoded data, check character, and quiet zone, with each character consisting of 3 black bars and 3 white bars.

Portion of the safety margin that is left when examining the element that has the largest width deviation (larger or smaller) from it’s intended value.

Element width becomes very important related to bar code growth or shrinkage. When an element that is to be a narrow bar begins to expand to the point where it can be misinterpreted as a wide bar the entire bar code becomes un-decodable or misinterpreted.

Check Character

Linear Character calculated from a weighted sum of all the characters

Defects Linear

Measure of the consistency of printed element widths as compared to the decode algorithm.

The lower the percentage the more chance for error until the percentage becomes so low and the bar code becomes undecodable.

Modulation Linear

QR Data Matrix

Measure of the uniformity of each of the peaks and valleys throughout the bar code.

Reflectance uniformity of a symbol’s light and dark elements

Finder Pattern

Data Matrix L shaped edge provides pattern detection and

orientation

Position Detection

Pattern QR

3 multiple box in box squares that locate and orient the symbol

Memory Area

QR Data Matrix

Contains coded data Amount of information determines size of

memory area

Clock Area QR

Data Matrix Number of rows and column information

Bar Code Standard

HSQM-0030 Page 3/6 4/01/2016

Definitions (continued)


Quiet Zone QR

Data Matrix

Zero information boundary Minimum white space around bar code

Axial Non-Uniformity

QR Data Matrix

The amount of X and Y dimension change Even scaling to the finder patterns

Grid Non-Uniformity

QR Data Matrix

The symbols deviation from the “perfect symbol”

How “out of square” the symbol is

Fixed Pattern Damage

QR Data Matrix

Damage to the finder pattern or the clock pattern

Pixels Per Element

QR Data Matrix

Number of pixels per element depends on the printers capabilities

Information only parameter

Print Growth QR

Data Matrix

Deviation due to printing problems Too much ink causes Overprint Not enough ink causes Underprint

Note: Above definitions obtained from IS as translated from ANSI X3.182-1990 (R1995), ISO/IEC

15415, ISO/IEC 18004, or ISO/IEC 16022 print quality standards.

Linear Bar Code Requirements

All linear bar codes must conform to ANSI X3.182-1990 (R1995) - Guideline for Bar Code Print Quality. This standard is used because all bar code verifiers accessible to Honda and suppliers in North America are set to measure based upon ANSI standards. To ensure scanability in the mass production environment, the following specifications are required.

Bar Code Standard

HSQM-0030 Page 4/6 4/01/2016

Specification Requirement

Bar Code Format Code 39 or 128. 128 is strongly preferred

Width of Quiet Zones Must be greater than or equal to 10 times the width of the start and stop character respectively.

Minimum Dimension of the Bar Code ( X Dimension)

The width of the Bar Code Element to be a nominal value of 0.165 mm or 10 mils. The height of the bar code element is to be a ratio no greater than 5 to 1, width to height.

Inter-character Gap Should be as close to the average narrow element as possible, i.e. should be the same width as average narrow element bar or space.

Wide to Narrow Ratio Must be 2.5 : 1 or greater

Minimum Reflectance Must be max5.0 R

Grade A

Symbol Contrast Must be %55 Grade B

Edge Contrast Must be %15 Grade A

Modulation Must be %60 Grade B

Decodability Must be %50 Grade B

Defects Must be %20 Grade B

Symbol Grade Must be a grade of B where B = 5.35.2 B Linear Bar code Grading Requirements

Item Requirement

Quality confirmation (labels only)

Bar code grading should occur at a minimum of 1 time per day for each printer. Best case is to confirm at each changeover. Also must confirm after printer adjustment and maintenance. Grading should include: 1) Grade bar code on a mass production part if possible. If this is not possible, the label should be placed on some test surface that mimics the part surface (i.e. contour, color, material, etc.) 2) Grading should be done in order to evaluate ALL ANSI categories. 3) Review bar code for visual abnormalities (i.e. waviness / distortion) and overall alignment 4) Evaluation of quiet zone

Linear Bar Code Requirements (continued)

Bar Code Standard

HSQM-0030 Page 5/6 4/01/2016

Linear Bar code Grading Requirements (continued)

Item Requirement


Print a solid black bar to ensure all print heads are working and not burnt out. This should be done daily for each printer.

2D Bar Code Requirements

Bar code scanability printed on labels must conform to industry standard ISO/IEC 15415 (Data Matrix) or ISO/IEC 18004 (QR) and achieve a grade of 4 (A) or 3 (B) to be acceptable. Bar code scanability printed on parts, DPM (Direct Part Markings) must conform to industry standard ISO/IEC TR 29158 (AIM DPM – 1 – 2006) and achieve a grade of 4(A) or 3(B) to be acceptable unless otherwise agreed upon by Honda and documented in an approved LNDD. This standard is used because all bar code verifiers accessible to Honda and suppliers in North America are set to measure based upon ANSI standards.

To ensure scanability in the mass production environment, the following specifications are required for printed on label 2D bar codes.

Specification Requirement

Bar Code Format QR or Data Matrix.

Width of Quiet Zones QR: 4 modules wide DM: 1 module wide

Minimum Reflectance Must be max5.0 R Grade 3(B) or higher

Parameter Grade 4(A) or 3(B)

Symbol Contrast Must be > 55 % Grade B or higher

Axial Non-uniformity Must be > 8% Grade 3(B) or higher

Grid Non-uniformity Must be < 50% Grade 3 (B) or higher

Modulation Must be > 40% Grade 3 (B) or higher

Bar Code Standard

HSQM-0030 Page 6/6 4/01/2016

2D Bar code Grading Requirements

Item Requirement


Bar code grading should occur at a minimum of 1 time per day for each printer. Best case is to confirm at each changeover. Also must confirm after printer adjustment and maintenance. Grading should include: 1) Grade bar code on a mass production part if possible. If this is not possible, the label should be placed on some test surface that mimics the part surface (i.e. contour, color, material, etc.) 2) Grading should be done in order to evaluate ALL ANSI categories. 3) Print a solid black bar to ensure all print heads are working and not burnt out. This should be done daily for each printer.

Fixed Pattern Damage 4(A)-0(F) grade on how well it can be decoded. Must grade a 3(B) or higher.

Minimum Reflectance Pass or fail on if the darkest module is less than half of the reflectance of the lightest module. Must grade a 3(B) or higher.

Modulation Uniformity of the reflectance of light and dark elements. Graded parameter 4(A)-0(F). Must grade a 3(B) or higher.

Defects Measure of voids in the symbol using a ratio of max module reflectance and the symbol contrast. Graded parameter 4(A)-0(F). Must grade a 3(B) or higher.

Quiet Zone

Honda requires 4 modules around all sides for QR symbology, 1 for data matrix (2 is recommended). Graded parameter 4(A)-0(F). Must grade a 3(B) or higher.

Symbol Contrast Value difference between light and dark symbol elements. Graded parameter 4(A)-0(F). Must grade a 3(B) or higher.

Note: Grading categories are in accordance with ISO/IEC 15415 or latest revision. HTRs Suppliers can receive an HTR for bar code problems. Please see the Index

procedure for more information on HTRs.

Designation of Quality Representative

HSQM-0129 Page 1/1 04/01/2019

Overview The supplier shall register its quality contacts (OEM Company QA Representative and OEM

Facility QA Representative) in Supplier Relationship Management database for effective quality communication with Honda.

Requirements

The supplier shall designate contacts for quality assurance to manage quality related operations with Honda and to facilitate thorough communication with Honda. Designation of Quality Contact The supplier shall designate qualified personnel to act as a contact to Honda for the following duties in accordance with roles and tasks.

OEM Company QA Representative – Corporate level manager responsible for implementation of company-wide quality assurance and quality control activities. Assume responsibility for the following as the representative for the supplier’s quality: 1) Attends Supplier Quality seminars organized by Honda 2) Complies with Honda corporate-level quality improvement requests 3) Responsible to deploy the Honda Supplier Quality Manual throughout the

company 4) Represents the supplier and participates in audits 5) Serves as the contact person to Honda for a corporate-level communication or

when Honda makes corporate-level requests to the supplier

OEM Facility Quality Representative – head of a factory or general manager level official appointed per supplier facility and responsible for quality assurance/ control activities. Initial Registration The supplier shall register all quality contacts in Supplier Relationship Management database. The supplier shall have a system/procedure that periodically reviews the content of SRM for accuracy. Change to Supplier Relationship Management database Supplier will immediately update Supplier Relationship Management database in the event of a contact person change or any other changed information immediately notifying Honda.

Supplier Quality Audit (QAV)

HSQM-0130 Page 1/4 04/01/2019

Overview

Honda shall conduct quality audits of suppliers’ sites. The supplier shall participate in the quality audit and take appropriate actions with respect to

the findings identified.

Definitions

The definitions of terms used in this manual are as follows.

No. Term Definition

1

Supplier In-House Auditor

For GQAV-1, a supplier associate selected by the supplier fromits o w n employees to lead assessment during a Quality Assurance Visit. (In Supplier Relationship Management database:“OEM Company QA Representative” and “OEM Facility QA Representative”)

2

Lead section of Honda

A section of Honda, which acts as a planning center for the Quality Assurance Visit and issues individual audit plans to notify suppliers of the audit

3 QAV Quality Assurance Visit

4 GQAV Global Quality Assurance Visit

5 Designated

Quality Representative

OEM Company QA Representative and OEM Facility QA Representative in Supplier Relationship Management database

Category of Audit

Honda may conduct the following types of audits (Quality Assurance Visits) at supplier:

No. Types of Audit Detail

1 Sourcing-QAV (S-QAV)

Audit of supplier quality system with a focus on Management, New Model Development, Training, Safety and Competitiveness.

2 GQAV-1 Audit is to confirm conformance and performance of supplier quality management systems, as related to Honda customer specific requirements for Global evaluation.

3 QAV-1 Basic

Audit is condensed version of GQAV-1 (to confirm conformance and performance of supplier quality management systems, as related to Honda customer specific requirements) for North American evaluation.

4 QAV-2 A QAV that does not fit within the above categories.


HSQM-0130 Page 2/4 04/01/2019

Audit Selection Reasons for audits may include but not limited to NM development, quality impact, horizontal confirmation, etc:

A supplier may be selected for S-QAV prior to the General Agreement for Purchase of Parts and based on: 1) Supplier may produce important safety parts 2) Honda may determine quality audit is necessary before entering into new

Purchasing agreement A supplier may be selected for QAV-1 Basic and/or GQAV-1 whenever it is necessary

to confirm quality management systems and verify the performance of those systems. A supplier may be selected for QAV-2 for any other visit purpose or confirmation

activity.

Scope of S-QAV The scope of S-QAV may include, but is not limited to: 1) Management 2) New Model Development 3) Process Control 4) Delivery 5) Quality Control 6) Manpower / Training 7) Sub Supplier Control 8) Safety 9) Competitiveness

Scope of GQAV-1

The scope of GQAV-1 may include, but is not limited to: 1) Quality Policy, Business Plan and Organization

Quality Policy and Business Plan Organization Structure 2) Quality System

Rules and Procedures Quality Assurance System Chart 3) Spec and Design Control

Spec Control Regulatory Compliance Certification Products’ Chemical Substances Control Product Design Control Process Design Control 4) Control of Standards

Inspection Standard PQCT Operation Standard Inspection Data Sheet 5) Supplier Control

Contract Audit / Evaluation / Guidance


HSQM-0130 Page 3/4 04/01/2019

Receiving Inspection (Delivered Parts) Change Point Control 6) Parts Control

Change Point Control Lot Control ID Control Quality Deterioration Prevention Control Honda Supply Parts Control 7) Process Control

Manufacturing Condition Control In-process Inspection Improvement on Non-conforming Parts in Process 8) Manufacturing Equipment Control

Manufacturing Equipment Control 9) Final Inspection and Reliability Test

Final Inspection Reliability Test / Adequacy Confirmation Test 10) Inspection Devices Control

Measuring Devices / QA Machines 11) Trouble Countermeasure and Deviation Acceptance

Trouble Countermeasure and Deviation Acceptance 12) Internal Quality Audit

Internal Quality Audit 13) Quality Education and Training

Quality Education (for each level) Department Quality Education / Training

Scope of QAV-1 Basic

The scope of QAV-1 Basic may include, but is not limited to: 1) Business Planning & Organization 2) Quality System 3) Spec & Design Control 4) Control of Standards 5) Supplier Control 6) Parts Control 7) Process Control 8) Manufacturing Equipment 9) Inspection & Reliability Testing 10) Inspection Devices Control 11) Countermeasures & Corrective Actions 12) Internal Auditing 13) Training 14) Development Organization 15) Production Control 16) Management System 17) Process Quality Control 18) Safety


HSQM-0130 Page 4/4 04/01/2019

Scope of QAV-2 The scope of QAV-2 may include, but is not limited to: 1) Receiving Inspection 2) In-process Parts/ Materials 3) In-process Quality (PMQ) 4) In-process – Equipment 5) Preventative Maintenance 6) In-process – Manufacturing Fixture 7) In-process – Manpower 8) In-process QA Machine 9) Inspection Fixtures/ Tools 10) Part Inspection 11) Non-conforming Parts 12) Rework/ Repair 13) In-process – Performance 14) Packaging/ Labeling 15) Off-line Testing 16) Documentation 17) General (problem tracking, cleanliness, etc)

Countermeasure Implementation

If necessary, the supplier shall, based on audit report issued by Honda, formulate an improvement plan and submit to Honda by the date specified. Honda may request changes to the implementation plan where necessary.

Quality Meeting

The supplier shall attend a quality meeting upon request from Honda, receive evaluation reports on the implementation, and verify effectiveness of the results of the measures.

CRF

HSQM-0017 Page 1/2 07/01/2015

The CRF The CRF (Countermeasure Request Form) is the Honda method used to request a change to a drawing and/or specification. A CRF is used to improve the overall quality, manufacturability, or cost of a part and/or completed vehicle. Additional areas of consideration are: Safety, Quality, Cost, Delivery or Morale improvement To meet government regulation and/or global circumstances Process improvement Correction of drawing error

Situation Appraisal

Before a CRF is submitted the supplier needs to have a thorough understanding of the situation/problem. Investigate the situation/problem How many times has the situation occurred in the market/testing When did the occurrences start Has this problem occurred at a specific location Is it a design or a manufacturing issue Has there been a design change to any parts Verify part specifications - questionable parts should be measured to help

determine if the problem lies in the design or in the actual part

Determine the Cause

Use the situation appraisal to help determine the possible causes of the problem. If the root cause is design, or the process is not capable of controlling, a CRF may be considered. CRFs are submitted if changing the design is the best option, considering ability/cost to control by process, cost to C/M design or affect to production. Note - data supporting the root cause analysis and chosen C/M improves the likelihood of CRF approval.

Determine the C/M

When determining the C/M keep the following in mind Will the C/M be effective Will the C/M cause secondary problems (Honda production, final

customer, components/system function) What is the cost impact and is it cost effective

CRF

HSQM-0017 Page 2/2 07/01/2015

Timing The targeted time period for CRF submission is during NM development prior to tooling kick-off, to help control the cost impact of the change. However, a CRF may be submitted during NM trials or MP. Keep the following in mind. "A" rank or safety related CRFs may be issued during any stage of a

model CRFs created to increase manufacturing capabilities, process/quality

improvements, etc. require a high cost merit or large quality/production impact

MP CRFs that don't meet cost merit or are not safety related are forwarded to the next NM project

Note - Honda notifies suppliers of the required CRF submission timing, for each NM project. Typically prior to tooling GO.

CRF Submission

Take the steps below to complete and submit a CRF. Obtain most current version of the form (PEDD, NMD, PQ or CPG

associates have access to the most current form) and an operation standard for filling in the form

Complete the form per the operation standard. If it is not completed according to the operation standard it will be returned for corrections.

Complete the form in English with a Japanese translation (when possible) Include all documentation, including cost calculations Submit to the proper Honda associate

Proper Honda Associate

The proper person to submit a CRF can vary by Honda location and may vary due to timing of the submission. Prior to submit, please verify with your current contact whom the proper associate is to review.

Honda R&D Honda R&D is responsible for final judgment of the CRF. If approved,

Honda R&D initiates and issues the specification change, when required.

Note – the CRF form is located in the forms section of this manual.

CRF Form Operation Standard

HSQM - Reference Page 1 05/01/11

Important Note The form and operation standard included in this manual are for reference

only. Before completing a CRF make sure you have obtained the most current revision of the form and the operation standard.

Filling out the Form

The table below explains information that is required for each section of the CRF. Any numbered item shown below is the supplier's responsibility. Honda is responsible for any item not listed here.

No. Item Entry/Description

1

DOCUMENT NAME

Countermeasure Request Form used to indicate the event name, etc. (a diagonal line is not necessary even if this column is not used.)

COUNTERMEASURE REQUEST FORM

(SSP)

Enter or stamp the event name etc. with parentheses

5

PAGE

Enter the page number as the numerator Enter the total number of pages as the denominator (e.g. 1/5, 2/5, 3/5, 4/5, 5/5)

6

REQUEST DEPT. APPROVAL SIGNATURE

Request from Suppliers Enter the company name, plant location, dept. name, and telephone number of the responsible contact.

DATE

Enter the date when signed off by the responsible person of in-house department or supplier.

CHARGE

Name of the individual issuing the CRF (Please write legible) 9 MODEL

TITLE

Enter the model type classification (Prototype code) of the applicable model(s). (e.g. S01Z, S02Z, or S82X, S87X, or S3MY)

• Confirm which models are impacted by the CRF. • CRF should include model types from only one model platform. (e.g. Accord, S82,

S87, or Civic, S02, S03) Enter a brief description of the request.

• The title should be concise, yet unique to the CRF. Thus easing future reference within the PEDD CRF Tracking System. Keywords are helpful. (e.g. IQS, Q10, VA)

10 EVENT vent timing during the creation of the CRF. If not required then draw a diagonal line.



Code Description1 To upgrade quality (excluding 2 to 5)

2 To upgrade durability (strength, weather resistance, heat/ cold resistance)

3 To prevent interference, to keep clearance (excluding wiring and piping)4 To improve wiring and piping5 To upgrade rustproof quality6 To upgrade marketability (excluding 7)7 To reduce vibration and noise, to upgrade drivability and riding comfort8 To improve maintainability9 To improve productivity (processability, workability)

10 To commonize11 For VA, cost reduction12 For re-layout by supplier13 To facilitate procurement14 To simplify parts control15 To conform to standard regulation16 For patent

17 Error corrections and rearrangement of HSS and drawings (excluding 18)

18 To rearrange drawing19 To issue finished drawing20 For vehicles already marketed21 To meet special demand22 To add specification (including KD)23 Others


11

VARIATION Enter the destination of the applicable models (e.g. KA, KC, KG, KJ, KM, or All ABS, non ABS, or LX, DX, Si)

12

REVISION NO.

Enter the latest Revision No. (design change level) of the drawing being referenced.

• Use the Honda Structure System (HSS) to confirm that you are reviewing the highest revision level of the drawing. This will inform the designer your analysis was based on the correct design change level.

• If the latest revision level of the drawing is not in the drawing files or Catia, then

request the drawing from the Specification Control Department (Spec. Control).

13

PURPOSE CODE NO.

Enter the applicable Purpose Code No.

LIST OF PURPOSE CODE NUMBERS



CODE DESCRIPTION1 Drawing issue for remaining items2 Defect on drawings3 Defect on HSS

4 Re-examination of engineering design (layout, interference, requirement)

5 Defect on test evaluation6 Defect on coordination in related dept. in HG

7

Improvement on assembly and processability which can only be pointed out by mass production line (request from line, request from suppliers, etc.)

8 Re-examination by plant, EG or supplier (defect on coordination between local suppliers division)

9

Unexpected external cause (effect from other companies, instruction from upper management, request for specification change from sales)

10 For event (for VA, meeting for lighting, check for ED application, wiring,maintenance, noise etc.)

11 Others


14

CAUSE CODE NO.

Enter the applicable Code No.

LIST OF CAUSE CODE NUMBERS

15 PART NAME DWG NO.

Enter the Part Name as indicated on the drawing • Not commonly used part names

• Enter the latest increment of the complete Drawing No. (e.g. 39100-S3V-A013-

M1, not 39100-S3V-)

• List the complete Drawing No. to guarantee that the correct drawings are reviewed and corrected by R&D.

• List all drawings that need to change. The list helps guarantee the designer will

not overlook additional drawings to which the change should apply. This will also provide you a confirmation list when the new drawings are issued.

• Base Part No., first 5 digits, should be identical unless Right/ Left (e.g. SIDE PNL

OUT COMP 63100/500). Remaining Part No. variables can be combined (Ex. S04, S03, S02, or ZZ00, ZY00).

• Create exclusive CRFs for complex changes that impact multiple parts. Reference

the applicable CRFnumbers on each CRF that is part of the complex change.

• Create exclusive CRFs if two unrelated requests effect the same part. Combining issues could create confusion when the designer agrees to countermeasure one request while disagreeing with the other.

• Confirm that all of the drawings listed need to be changed. Do not guess or make

assumptions.




16

DESCRIPTION

Enter the problem description in detail. Use illustrations for improved communication/ understanding. Contents must be written in both English and Japanese for CRFs designated for HGT evaluation. Purpose:

1) Convince the designer that the issue is a design problem which requires a drawing change. (Safety, Quality, Cost, Delivery).

2) Prove to the designer that you have researched the problem and fully understand the situation (establish credibility with the designer).

• Make the request self-explanatory. In many cases R&D will receive the CRF for

evaluation without the opportunity for further discussion.

• State the problem. State what will happen if the drawing does not change. State the potential worst case scenario (e.g. AF cannot install part to car, Supplier cannot manufacture part to the drawing, Bracket edge cuts harness). Supporting data is required.

• Include a sketch/ photograph of the problem area of the car, if required.

• Include a sketch/ photocopy of the current drawing (before countermeasure), if

required.

• Include a copy of the HSS printout if the request involves application errors.

• If the request requires a Catia layout for support, include the Part No. and design change level for all parts in the layout.

• If the request involves a manufacturing process, explain the process sequence.

• Include supporting information with appropriate signatures.

For example • Insertion force too high = insertion force data and the assembly plant’s

requirements (PQ, AF, EHSD) • Not enough harness length to install = manufacturing’s minimum requirements

(AF) • Squeak & rattle problem = analysis report (PETD, VQD) • Warranty issue = warranty data (MQD) • Cost reduction = current and proposed cost figures (CPD)

• Include graphs, charts, and illustrations rather than written paragraphs whenever

possible

Remember- the CRF may be evaluated by someone who does not understand English as well as you do.




17

PROPOSED C/M

Enter the countermeasure idea in detail. Use illustrations for improved communication/ understanding. Contents must be written in both English and Japanese for CRFs designated for HGT evaluation. Purpose:

1) Convince the designer that your proposed countermeasure will effectively solve the problem. (Safety, Quality, Cost, Delivery)

2) Assure the designer that all investigation avenues have been fully evaluated. If additional information remains pending, list the expected information and target date.

• Include a revised sketch/ photocopy of the drawing incorporating the exact

changes requested. (after countermeasure), if required.

• The request should represent the originator’s specific requirements.

• Explain how the proposed countermeasure effectively eliminates the problem. The countermeasure should be 100% effective in eliminating (designing out) the problem, and not just an improvement.

• If a temporary countermeasure required a Manufacturing Instruction (MI) to be

issued, include MI No. in Proposed Countermeasure Section to emphasize criticality of the request. Also attach cover page and drawing to the supplemental pages.

• Do not downgrade the contents of the request to less than what is required based

upon what the designer will approve. If the designer does not fully approve/ implement your exact countermeasure, this will allow you room to revisit the issue at a later date.

• If the designer implements exactly what was requested per the CRF, and it does

not satisfy your needs, you have little room to negotiate for additional changes in the future.

• If you are unable to confidently give an exact countermeasure, state the

requirements. (e.g. required dimension change = minimum: 15mm of clearance, required for part to be installed).




18

EFFECT

Enter the impact negotiated by the Supplier and Purchasing OLD: Prior to revision NEW: After the revision DIFF: Variance

1) COST DIFFERENCE: Calculate the cost variance

2) WEIGHT DIFFERENCE: Calculate the weight variance

3) INVESTMENT: Cost incurred for future benefit (e.g. Die modification)

4) LOSS: Cost to be written off (e.g. Die scrap)

5) OVERHEAD: Honda use only

6)DIE MODIFICATION SCHEDULE: When Die Modification is required, obtain confirmation of the schedule by Die Modification Dept. with signature (attach schedule). Schedule should include die modification time and time to complete testing required to validate the change.

Note: If the item has no impact a diagonal line must be drawn.



CRF Form Operation Standard Addendum for Honda Power Sports Products (PSP)

Scope The following Matrix describes the Purpose and Cause Codes that are used specifically for Honda

PSP. These codes are to be used for CRF’s that are applicable to product manufactured at HSC, HPE and HDM.

Important Note 1

Important Note 2

The actual CRF is the same as contained in this manual. The code differences are necessary due to unique processing systems used by the applicable Honda R&D divisions. All other information is required to be completed as shown in the current CRF Form Operation Standard. For additional completion support, please contact your Honda assigned Supplier Rep.

PURPOSE CODES

Purpose Codes are used to identify and summarize CRF purpose for R & D categorization. 1 Marketability Improvement (Outside Appearance, Reliability, Operability, Comfort, Functionality)

2

Productivity Improvement (Yield, Formability, Workability, Machining Accuracy, Heat Treatment, Surface Treatment)

3 Workability Improvement (Operability, Ease Of Assembly, Control)4 Ease Of Sourcing (M/L Change, Category Change, Manufacturing Method Change)5 VA , Cost Down (Commonality, Weight Reduction)6 Serviceability Improvement (Maintainability, Service Parts)7 Social Compliance (Regulations / Standards Compliance, Environment)8 Activities For Patents 9 Drawing Release Processing (Drawings Not Issued, Re-drawings, Mis-description Correction, BOM Correction)

10 Others CAUSE CODES

Cause codes are used after the initial drawing release and gebas to determine why the issues were not found earlier. This data can be used to justify manpower/training/development tools in order to achieve earlier design maturation.

CODE

DESCRIPTION

CLARIFICATION (reason not found before)

1

Drawing issue for remaining items Layout / data / spec was not available before. Data incomplete before.

2

Defect on drawings New defect on drawingPrevious request not reflected or reflected incorrectly

3

Defect on HSS New defect on HSSPrevious request not reflected or reflected incorrectly

4 Re-examination of engineering design (layout, interference, requirement) Was on previous drawing / data before but missed

5 Defect on test evaluation Problem found by performance / functional test

6

Defect on coordination in related department in HG

Design changed spontaneously by R&D after die go which affected manufacturabilityNew part added

7

Improvement on assembly and process ability which can only be pointed out by mass production line (request from line, request from suppliers, etc.)

Could not detect without actual part and/or CBUCould not detect problem without MP timing, quantity or equipment / fixturesTolerance stack or CBU condition different than theoretical condition

8

Re-examination by plant, EG or supplier Prototype tool / equipment did not identify problemMP equipment capability reexamined

9

Unexpected external cause (effect from other companies, instruction from upper management, request for specification change from sales)

Expectation changed (ex: new information about market, evaluator reject requiring changes, etc.)

10 For event (for VA, meeting for lighting, check for

ED application wiring, maintenance, noise etc.) Not normally used

11 Others Not normally used

Inspection Data

HSQM-0032 Page 1/3 04/01/2019

Background The supplier takes data to guarantee the process consistently produces good parts. Supplier shall collect and retain appropriate data to validate parts and production regardless of Honda’s request for data submission. Frequency of taking data depends on process capability.

Reasons Honda Requests Data

Honda may require data to be periodically submitted. Some example cases are listed below. To comply with a regulation testing requirement To comply with an agreement between Honda and a regulatory agency To verify process capability To evaluate process assurance capability verification (PAC-V) during new model

development To investigate suspected part problems To verify the quality level for part approval (e.g. MP IPPAAR, NM part approval or

QAN) Part data may be required for each New Model trial event and at other times. Other as requested by Honda

Regulation Part A regulation part is one that must meet the requirements of the countries to which Honda products are exported. These countries include but are not limited to Japan, the European Union and China. Honda notifies the supplier of each part that is a regulation part. Honda also works with the supplier to ensure they both clearly understand the data required, the frequency of collection, the number of samples, and the frequency of submission. The inspection items for each regulation part are required to be included on the PQCT.

Inspection Data

HSQM-0032 Page 2/3 04/01/2019

Process Capability

Any time there is a new or changed part/process a capability study is required to confirm that MP manufacturing processes are statistically capable of producing parts within a given tolerance. The capability study is submitted with any other required approval documentation (e.g. MP IPPAAR, NM part approval or QAN). Requirements of a capability study include Identify which critical dimensions/characteristics need to be included in the

process capability study Identify which pieces of equipment and/or fixtures need to be evaluated Review proposed scope of capability study with Honda quality contact Set final agreement on requirements Perform the study (n = 30 or negotiated quantity) and summarize the data (take

random samples, consider all populations requiring discrete study – e.g. all shifts)

Evaluate the data, analyze risk and set follow-up activity based on the following criteria

Submit capability study to Honda for review and final agreement Set follow-up plan/schedule for Cpk levels which fall below the 1.33 target Note: Honda will notify the supplier if special control is required based on

special part fit or functional requirements.

Cpk Action

> 1.33 High Quality - no action required < 1.33 , > 1.00 Increased inspection, lot acceptance testing and countermeasure

plan required < 1.00 100% inspection and countermeasure plan required

Inspection Data

HSQM-0032 Page 3/3 04/01/2019

Data Requirements

The supplier is responsible to collect timely and accurate data at the specified frequency. The supplier's management reviews and approves the data prior to submitting to Honda. The data may be in a format of the supplier's choosing provided the following are included: Honda part number Honda part name Specification and tolerance required to meet Actual numerical results, where applicable Indication of any data that is out of specification Each result identified by sample number Method of collection Each sample identified by lot number, production date/time, or other

means to connect known production conditions to the sample Identification of the associate collecting the data Approval of the data by supplier management

Data Submittal

Honda requires different data to be submitted at different intervals. Some data is required daily, monthly or as requested. Honda normally specifies the submission timing for each data request. Honda may also require data to be collected and held by the supplier for Honda review during a QAV or to be sent to Honda only upon request.

New Model Timing Timing Purpose Requirements

PA-2 Supplier submits draft

Inspection Data Sheet Supplier/Honda Review

Supplier develops inspection criteria with NM/PQ input Supplier provides Inspection Data Sheet draft NM/PQ confirms critical control items based on

specification/drawing review and previous model NM/PQ feedback any change points to supplier

PA-3

Supplier updates & submits Inspection Data Sheet

Honda confirms Inspection Data Sheet

NM/PQ confirms that all inspection items are included and agree to with supplier

If a D/C occurs, NM/PQ confirms any change points that may need to be modified

PA-5

Supplier/Honda confirm latest event data

Supplier c/m’s accuracy concerns

NM/PQ receives inspection data from supplier before each NM trial event

NM/PQ reviews the data for content and ensures the part meets the trial event target

Supplier must confirm all drawing dimensions by layout

Specified Action Plan (SAP) Purpose and Outcome

Establish a dynamic plan that will achieve the desired results

Expected Outcome

• Gain an understanding of the contents of a comprehensive SAP

• Proactively plan for success from your project rather than making a schedule to be checked

• Consider more inputs and outputs for a robust plan

• Increase visibility of the project and responsibilities

• Include metrics and management review to assure the actions are achieving the targets and provide PDCA (Plan Do Check Act)

• Manage obstacles that may add risk to your team’s actions

Specified Action Plan Global Viewpoint

G

SAP

GLOBAL Sharing & Horizontal Application of Best Practices

Establish a global organization and SAP that will guarantee target achievement.The North American voice must be strong – using global viewpoints.

Plan for

SAP Expectations

# Category Confirmation Item Why is this important What is the tool

1 SA/Reflection/StrategyReflect previous and upcoming environment changes (new lines, new model start up including other customers) into strategy.

Ensure lessons learned are incorporated into strategy to prevent problem recurrence.

Quality & Deliveryperformance trends, PPH, NM schedules

2 SA/Reflection/ StrategyIncorporate Honda event and improvement strategies to ensure strong linkage into SAP actions.

Ensure strong linkage in SAP to Honda strategy. Cascade to sub‐suppliers who are part of the plan.

Communication from Honda

3 OrganizationEstablish clear roles and responsibilities from a global viewpoint. The project organization includes key members from a cross functional team.

Project success is dependent on the resources selected and allocated. Collaboration between all departments (Design and Manufacturing facility, etc.) and all regions.

Organization Chart

4 CommunicationClearly identify the global organization and communication method and route.

Clear communication through all levels of the organization is needed to effectively manage the project including an escalation procedure for support.

Organization Chart

5 Roles & Responsibilities

Identify roles and responsibilities Consider other demands in the work environment competing for resources (ex. New model launches, new production lines).

Clear responsibility is identified for project tasks’ completion.

Organization Chart

6 Honda EventsIdentify the Honda progress checks on the SAP. Link all activity to meet expectations on time.

Honda requirements must be clearly understood to align SAP detailed actions and requirements to meet expectations.


7 Goals/Targets

•Establish internal targets Clear linkage to project goals and plans between Supplier and Honda are needed to achieve targets. Expectations are clearly understood to streamline the improvement and review process.


•Link SAP to Honda targets

8 Goals/Targets Establish a Sub‐supplier subset of internal targets.Each Supplier shall have their own internal subset of targets directly linked to the SAP to achieve Supplier internal and Honda targets.

SAP

9 Goals/TargetsSet interim targets and key triggers for critical activity leading up to each of the project milestones.

Critical activity must be managed based on risk. Prioritize critical tasks on the SAP.

SAP

10 Goals/TargetsProject goals/targets must be S.M.A.R.T. – Specific, Measurable, Attainable, Relevant, Time Bound.

Project goals/targets must be tangible. SAPHSQM‐0016

SAP Expectations

# Category Confirmation Item Why is this important What is the tool

11 Reanalysis of past problemsA cross-functional team reanalyzes past problem symptoms with why-why analysis to identify gaps that allowed the problem to occur and not be detected.

True causes of problems must be uncovered to prevent reoccurrence. Why-Why Analysis

12 Develop countermeasure activities

Actions are developed to countermeasure the systemic causes. Each action has interim targets.

The probability of achieving targets is greater if an adequate amount of actions are developed. Measuring to interim targets informs if an action is not effective or not implemented as planned.

SAP

13 Evaluations Include timely Supplier internal top management evaluations linked to project milestones.

Supplier top management must be involved at a corporate level to evaluate the project status and ensure necessary resources have been allocated to guarantee success.

SAP

14 SAP GapsEnsure gaps that are identified are flagged on the SAP and reported on a gap sheet to ensure strong communication and gap closure activity.

Communication of open items within the team and to Honda to ensure strong gap closure activity. Gap Sheet

15 Plan vs Actual Each task must have a planned start and finish date, record of changes to the plan and tracking of actual.

The entire project team, including top management, must have clear visibility of the original plan, revised plan, start, finish, and implement a recovery plan where necessary.

SAP

16 Reporting FrequencyEstablish reporting frequency-link to risk ( i.e.: High level Senior Mgmt). Establish milestones and determine Who and When to review.

Project reporting is essential at all levels throughout the organization to communicate the project status and receive PDCA support from management.

SAP

17 EvidenceEnsure accurate data is available to confirm activities. (for example, worksheets checking CCP connectivity from PFMEA down through working documents).

Backup data is the evidence required to evaluate the details and measure the results of all tasks on the SAP.

Tracking worksheets

18 Management Apply PDCA logic. Revise and report gaps accordingly for each action item line.

We must continuously rotate the Plan, Do, Check, Action (PDCA) cycle in our dynamic environment and be flexible to adjust accordingly.

SAP

19 ManagementEstablish management system, reporting frequency and escalation triggers. Maintain gap reports with updates based on risk.

The entire project team, including top management, must have clear visibility of the project status and implement action plans when necessary.

SAP

20 Project CompletionDetermine when the project activities are complete, all gaps are closed, and metrics indicate targets set by Honda and Supplier are achieved.

Ensure effective systems and controls are fully implemented with metrics that confirm results.

Supplier and Honda Management Review HSQM‐0016

SAP Expectations – Situation Analysis

1. Reflect previous and upcoming environment changes into

strategy

What was happening in our environment at the time of the problems?

?

Honda GQI trigger ?

Key RequirementsThe Situation Analysis must be complete for past,

present and future with accompanying countermeasures driven into the SAP.

Key RequirementsThe Situation Analysis must be complete for all top concerns. Use reflection of past problems

into the strategy.

HSQM‐0016

SAP Expectations – Situation Analysis

2. Incorporate Honda events and strategies to ensure strong

linkage into SAP actions

HSQM‐0016

4. Clear Project Team to effectively manage, including communication

and escalation route

SAP Expectations – Organization / Roles & Responsibilities

5. Responsible individuals5. Responsible individuals

3. Clear GLOBAL organization, support from ALL Regions, resources allocated

HSQM‐0016

SAP Expectations – Organization / Roles & Responsibilities

Project SpecificOrganization Chart

Complete CompanyOrganization Chart

Project ‘Lead’ Quality Manager

A. SmithProject Commitment

75%Pilot Commitment 25%(Backup = C. Jones)

Example

Key Requirements Clearly defined and documented Organization Roles and responsibilities defined and documented Honda and other OEM experience taken into account All members of the Team identified Defined reporting flow Back-up associates identified Top Management participation Establish the SAP in the first month and keep updatedHSQM‐0016

SAP Expectations – Honda Events

6. Honda Activity Targets Template6. Honda Activity Targets Template

Link activities to meet expectations on timeLink activities to meet expectations on time

HSQM‐0016

SAP Expectations – Goals / Targets

7. Establish internal targets taking into account expected

improvements with their timing

Honda GQI

triggerSupplier GQI target

HSQM‐0016


Honda Targets Past A Rank Reanalysis

FTA Verification

Confirm rules of CCP 4M viewpoints confirm QA at manual operations

Conduct special char audit

Honda and supplier checks

SAPWhy Why Analysis A Rank

CCP point confirmation

Check CCP captured all levels of documents

4M judge CCP and improve

Visual management

Management genba checks

Verify QA of CCP at manual operations

Establish special char audit

7. Clear link between the Honda targets and the SAP

HSQM‐0016

Purpose


8, 9, 10 Establish internal targets / triggers

Format

Establish Project Goals Based Off Current Environment and Previous Models’ Reflections

Divide the Goals Into Manageable TasksDefine When to do the TasksAssign Responsibility for Completing TasksTrack and Evaluate Progress of Each Step

Honda does not require a specific format for the SAP. However, Honda does require certain components:

Org. Charts – global and localSupporting SAP’s within supplier’s organization

Goal SettingProgress TrackingEvaluation Process Method

Honda and Supplier Goals must be S.M.A.R.T Specific – Measureable – Attainable – Relevant – Time Bound

HSQM‐0016

SAP Expectations – Reanalysis of Past Problems

Use pareto analysis to identify the largest problems

in past performance. List the highest impact problems

first.

Use data to identify the largest types of quality problems

Ex. Missing weldPareto analysis

These 3 defects = 79% of quality failures

HSQM‐0016

Y ‐ Y Training ( Problem Solving

Follow up List (Why Made)

Due Date Priority Who Comments Path Forward Action Who

9/8/2017 JREM is working to

Improve PM system

and have less of these

issues

Keep pushing

forward to improve

PMs and create less

pump issues

Add to PM check

sheet Chuck V.

9/8/2017 JR

EM is working to

Improve PM system


issues

Keep pushing

forward to improve

PMs and create less

pump issues (

possible application

for Heat Gun)

Add to PM check

sheet Chuck V.

Problem Statement ‐ Aluminum Chip in the 5 M6 EOP holes

Investigation outcome

Coolant pumps come standard with stainles screens but over

over time they rust due to not cleaning them and chip

buildup eats through screens causing pumps to be damaged

Average pump life is approx 10 years in proper conditions

This would be more true if we were able to keep up with PMs

on coolant tanks and verify the pumps are operating

Root cause drill down

NG Coolant Flush

Clogged Pump

Dirty Coolant Tank

No PM on Tank

24/7 Operation

Production Target not hit

Excessive Downtime

Equipment Issues

Age/ Lack of PM

NG Coolant Flush

Pump not work

Age/Rusted Screen material

NG material

Begin with Defect #1

from pareto

Identify all possible causes (mind map, fish

bone, etc.)

Defect 1 Problem Statement ex. Missing weld

Identify gaps for improvement

Root Cause Analysis training is

available from Honda SQD

Why Made

List all root cause branches for investigation

Why Shipped

Use cross functional team Use brainstorming rules Identify root causes by 4M:

Man

Machine

Material

Method

Material

Machine

Method

Man

Material

Machine

Method

Man


HSQM‐0016

Y ‐ Y Training ( Problem Solving

Follow up List (Why Made)

Due Date Priority Who Comments Path Forward Action Who

9/8/2017 JREM is working to

Improve PM system


issues

Keep pushing

forward to improve

PMs and create less

pump issues

Add to PM check

sheet Chuck V.

9/8/2017 JR

EM is working to

Improve PM system


issues

Keep pushing

forward to improve

PMs and create less

pump issues (

possible application

for Heat Gun)

Add to PM check

sheet Chuck V.

Problem Statement ‐ Aluminum Chip in the 5 M6 EOP holes

Investigation outcome

Coolant pumps come standard with stainles screens but over

over time they rust due to not cleaning them and chip

buildup eats through screens causing pumps to be damaged

Average pump life is approx 10 years in proper conditions

This would be more true if we were able to keep up with PMs

on coolant tanks and verify the pumps are operating

Root cause drill down

NG Coolant Flush

Clogged Pump

Dirty Coolant Tank

No PM on Tank

24/7 Operation

Production Target not hit

Excessive Downtime

Equipment Issues

Age/ Lack of PM

NG Coolant Flush

Pump not work

Age/Rusted Screen material

NG material

Standard Ctrl

Standard PM

Equip Design

Supplier Ctrl

• Provide evidence / data to eliminate possible causes that have controls in place for prevention and/or detection

• Prioritize causes based on risk

trol

Goal: develop improvement themes

Man

Machine

Material

Method

Training

List root causes and develop CM

for each root cause

Identify systemic

countermeasure themes for SAP

Each branch of the root cause drill down, bottom line is the

root cause

Establish due date for each investigation

Prioritize based on risk

Assign responsibility

In the “Results of investigation”: record evidence to confirm

PDCA or gap

Establish path forward for

countermeasure

Additional comments

Action to be

completed

Assign responsibility for action completion

Priority Key

High Priority

Medium Priority

NO counter measure needed

Cause for another problem ‐ save for future root cause analysis


HSQM‐0016

SAP Expectations – Develop Countermeasure Activities

12. Actions are developed for each improvement theme. Each

action has an interim target, each theme has metrics

Specific activities and control points strengthen the improvement plan

Enough CM are planned to achieve

the target

HSQM‐0016

Supplier top managementreviews at genba

Supplier top managementreviews at genba

SAP Expectations – Evaluations

Plan to complete internal evaluations with management prior to Honda evaluations according to the schedule.

HSQM‐0016

SAP Expectations – SAP Gaps

Use a gap worksheet to list gaps to ensure

strong communication and track gap closure

activity.

Communicate open items within the team and to Honda to ensure strong gap closure activity

HSQM‐0016

SAP Expectations – Plan vs. Actual

Each task must be managed by the SAP with the project team and top management reacting to changes

HSQM‐0016

High Med Low

No C/M plan in place. Risk to MP and/or

upcoming event

Temporary C/M plan in place, no risk to MP or upcoming

event

C/M plan in place, no risk to MP or

upcoming event

High Med Low

Items are reportedby PL to LPL dailyuntil item is deemedto be Medium Risk.

Items are reportedby PL to LPL dailyuntil item is deemedto be Low Risk.

Items are reportedby LPL to Sr. Mgmtdaily until item isdeemed to beMedium Risk

Items are reportedby LPL to Mgmtgroup at weeklymgmt meeting untilitem is deemed to beLow Risk.

Items are reportedby PL to LPL weeklyat project statusmeeting until item isclosed.

17 Back up data is available for all actions on the SAP

SAP Expectations – Reporting / Evidence

16 Reporting frequency and level are based on risk

Determine reporting frequency and schedule based on priority of the task, then support reports with evidenceHSQM‐0016

SAP Expectations ‐ Management

18, 19 ManagementAssure Continuous PDCA, management

system in place, reporting and escalation triggers, report gaps and updates based on risk

18, 19 ManagementAssure Continuous PDCA, management

system in place, reporting and escalation triggers, report gaps and updates based on risk

HSQM‐0016

SAP Expectations – Project Completion

Key Requirements for Completed Status Gaps are closed on each step Specified Action Plan Milestones are achieved Specified Action Plan Actions are judged effective Minimum 6 consecutive months with zero A-Rank Minimum 6 consecutive months with GQI < 151 Supplier internal targets for A-Rank and GQI are met Management review process with PDCA is sustainable long term to maintain

improvements

Safety Declaration

Example of a set of project completion requirements:

HSQM‐0016

SAP Best Practices – Top 10 List

Do1. Gain commitment and involvement of

the higher organization structure

2. Link your goals to Honda goals to meet customer expectations

3. Proceed only after reflection of pph

4. Consider cross‐functional team deep root cause analysis the most important activity using data to drive solutions

5. Divide corrective actions into system improvement themes (e.g. Standard Work)

6. Assign specific responsible associates to tasks (actions items)

7. Give each task a specific, quantifiable target

8. Obtain top mgmt. SAP review with sign off to assure support

9. Schedule periodic management reviews to assure resources to provide efficient PDCA to guarantee your actions will achieve your targets

10. Use visible internal metrics to communicate Plan / Actual schedule and achievement results

1. Try to fix systemic problems at only a local level

2. Set goals without regard to customer requirements

3. Jump into making a plan without considering what failed prior

4. Let one or two “seasoned” associates decide countermeasures to the causes based on opinions rather than data driven analysis

5. Make one large corrective action “shopping list” that overwhelms the responsible associates

6. Assign a team name to a task rather than an individual (“if everyone thinks someone else is doing it, no one is”)

7. List tasks without an image of what success looks like in numerical terms

8. Issue a SAP without top mgmt. review and approval

9. Let hope be your plan to keep the plan moving forward. Don’t forget to confirm your plan is effective – are you achieving the desired targets?

10. Inadvertently hide the status of the SAP from associates affected

Don’t

HSQM‐0016

Specified Action Plan (SAP)

HSQM-0015 Page 1/1 06/03/02

Background The SAP is used to Establish goals Break the goals into tasks or jobs Define when to do the tasks Assign responsibility for completing tasks Track and evaluate progress of each step

Application Although used primarily for New Model development activity the SAP

concept can be used for any activity that requires a schedule to achieve a defined goal. The complexity of the SAP will of course vary from project to project.

Requirement Suppliers are required to create a SAP for each new model project. Based on

part rank and each plant’s requirements; suppliers may be required to periodically submit the SAP to Honda for review.

Format Honda does not have a specific format for the SAP. Honda does however

require that certain components be a part of whatever new model development process a supplier uses. Goal setting Job tree Progress tracking Organization Evaluation process SAP within the supplier's organization The following pages contain reference material explaining the components of the SAP process.

Supplier Part Schedule (SPS)

HSQM - Reference

Background Suppliers are responsible to document and communicate NM part

development schedules to Honda PH. This is required for all new or changed parts that apply from the launch of a new model.

Responsibilities Honda PH communicates the project requirements to the supplier, coordinates supplier feedback, evaluates supplier feedback against the NM project targets and negotiates any necessary schedule adjustments.

Suppliers complete and submit the schedules according to the requirements.

Two Documents

The SPS is comprised of two documents. Tool Summary Sheet • Summarizes the critical path lead time for a purchased part

• Identifies high level change points to tooling, equipment and process

• Tracks the impact of each design change on tool maturation - by event Note - Honda PH issues a project specific version of the tool summary sheet for each NM project Gantt Chart

• Summarizes, in detail, all activities the supplier undertakes to ensure the

timely development of a part

• Content requirements - The schedule must explain plan vs. actual activity for each exclusive tool, piece of equipment, process and testing associates with the part. Honda PH provides a summary of development targets via the NMR process. Ideally the supplier's schedule incorporates all the NMR items.

• The format is flexible. However, Honda PH suggests suppliers use Microsoft Project to create the Gantt chart.

Timing A completed SPS is due from the supplier to the responsible Honda PH (NM) contact

• within 14 calendar days of the tool release

• Within 14 calendar days of receiving a new drawing or data - in order to quickly communicate the impact of each design change

• Once per month after tooling release until the part receives full approval from Honda PH - in order to report the progress of the part's development

Supplier Part Schedule (SPS)

HSQM - Reference

Tooling Terms The list below explains Honda's tooling terms

Term Explanation Go 1-1 Honda PH's authorization for the supplier to begin tool design

Go 1-2 Honda PH's authorization for the supplier to purchase long lead raw material for a tool OR to begin rough cutting

Go 2-2 Honda PH's authorization for the supplier to begin tool manufacture

MP In part maturation codes this code indicates the part's tooling and production process are MP ready

Related Documents and Activities

The table below lists related documents and activities

Document /

Activity Description

Design Change Instruction Sheet

A document issued with each design change from the Final Prototype Drawing issuethat authorizes the supplier to implement a design change within a specified timeframe. The supplier pulls information from the Design Change Instruction Sheet, in order to complete the “design change impact to tooling” section of the Tool Summary Sheet.

NMR

A process by which Honda PH reviews the development progress of select suppliersto ensure that the project is progressing satisfactorily. Suppliers are selected for reviews based on a calculated part rank. ‘S’ and ‘A’ rank part suppliers are required to present a SAP as part of the NMR process.

Start-up Plan

A document issued by Honda PH prior to event order activity that communicates general event requirements and timing. In early development, the supplier uses the delivery date information from the Start-up plan to establish the tool maturation plan, for each event, on the Tool Summary Sheet

Supplier NM Development Status Summary Sheet

A document used in the NMR process to report the supplier’s progress for each part against measurable project targets. The targets established on this form for each model drive the SPS Gantt chart content.

Tool Maturation Definitions

A document that explains what tooling and process criteria a part must meet in orderto satisfy a specific maturation code (can be found in the appendix of this manual).

Tool Release

A process by which Honda PH authorizes suppliers to proceed with tooling and equipment development. The information the supplier provides on the Tool Summary Sheet is used to determine the tool release requirement for each part.

Trial Matrix

A document issued by Honda PH to suppliers during the event order phase to communicate detailed trial event requirements and timing. Later in development, the supplier refers to the Trial Matrix to establish the supplier tool maturation plan for each event, on the Tool Summary Sheet.

Job Tree

PROGRESS TRACKING

GANTT CHART

August September October November December January February March April May June Jul

ID Task Name Baseline D Baseline Sta Baseline Fin 29 5 12 19 26 2 9 16 23 30 7 14 21 28 4 11 18 25 2 9 16 23 30 6 13 20 27 3 10 17 24 3 10 17 24 31 7 14 21 28 5 12 19 26 2 9 16 23 30

1 4 DOOR TRIALS 0 wk Wed 8/15 Wed 8/15 8/15

2 2 DOOR TRIALS 0 wTk asWked 8f/1r5omWed 8/15

8/15 EG UF-1 Dankaku QC

3 SPEC. MATURATION 1 wk Wed 8/15 Tue 8/21/

4 Design/Specification 1 wk Wed 8/15 Tue 8/21 mit CRF

5 TOOLING 26 wk Wed 8/15 Tue 2/12/

6 Tooling #1 - 2 molds 4 cavity 18.4 wk Wed 8/15 Thu 12/20

Milestones

7 Go-1 to Go-2 3 wks Wed 8/15 Tue 9/4/

8 Tool design 3 wk Wed 8/15 Tue 9/4/

9 Raw Material order 3 wk Wed 8/15 Tue 9/4/

10 G0-2 to T1 13.4 wk Wed 9/5/ Thu 12/6/

11 Cut Die Holder 25 day Wed 9/5/ Tue 10/9

12 Cut Electrode 10 day Wed 9/5/ Tue 9/18

13 CMM Carbon Electrode 2 day Wed 9/19 Thu 9/20

14 EDM Cavity 4 day Fri 9/21/ Wed 9/26

15 CMM Cavity 2 day Thu 9/27 Fri 9/28/

16 Finish Die cutting ~ Polish / 4 day Mon 10/1 Thu 10/4

17 Make / install cores and slid 10 day Fri 10/5/ Thu 10/18

18 Polish die 6 day Fri 10/19 Fri 10/26

19 Install water / electric lines 4 day Mon 10/29 Thu 11/1

20 Try 1 da Fri 11/2/ Mon 11/5

21 T1 - T3 2 wks Fri 12/7/ Thu 12/20

22 Part Accuracy changes 1 wk Tue 11/6 Mon 11/12

23 Process changes 1 wk Tue 11/13 Mon 11/19

24 Boat Ship tool from Japan 4 wk Tue 11/20 Mon 12/17

25 Set up 1 wk Tue 12/18 Wed 12/19

26 Try 2 day Thu 12/20 Thu 12/20

27 T-3 to T-4 3.4 wk Mon 1/21/ Tue 2/12/

G0-1 G0-2 T1

d/c R4Y-2-1234 Delayed go 2 by 2 weeks.

expedite to make up for late Go-2

expedPite tloamnake vupsfor AlatecGtou-2 al expedite to make up for late Go-2

T3

T4

Example

% Progress Completion

HSQM - Reference 1 06/03/02

Part Maturation Definitions

HSQM-Reference Page 1/1 04/03/17

Part Dimension Texture

Prototype (PR)

・Part not produced on MP Tool. Prototype tooling is temporary tooling not intended for MP use.

Prototype Meet drawing Handwork allowed

No Texture Required

Temporary allowed Temporary allowed Temporary process and

sequence Temporary

allowedNM associate /

Engineer No restriction

T1 ・Produce with MP toolMP Tool

(except blank, trim, pierce, bender)

Meet drawing Handwork allowed

No Texture Required

Temporary allowed

・MP inspection fixture available・Temporary

allowed

Temporary process and sequence

MP material and Country

of origin

NM associate / Engineer No restriction

T2 ・Produce with MP tool for all processes MP Tool

Meet drawing Handwork allowed

No Texture Required

Temporary allowed

・MP inspection fixture available・Temporary

allowed

Temporary process and sequence


of origin

NM associate / Engineer No restriction

T3

・Performance is equivalent to MP and enables start of PV test・Enable a Texture-Go for texture parts

MP Tool Meet drawing without handwork

Texture Ready

Equivalent to MP MP Process equivalent to MP

/ Sequence is MP


of origin

Engineer / NM / MP associate No restriction

T4(Texture parts

only)

・Texture applied and allows for appearance evaluation MP Tool Meet drawing

without handworkTexture

Required Equivalent to

MP MP Process equivalent to MP / Sequence is MP


of origin

Engineer / NM / MP associate No restriction

LT ・MP conditions for all processes except mass production volume MP Tool Meet drawing


Required MP MP MP process and sequence


of origin

MP associate (any shift)

MP final location

MP ・MP assurance is guaranteed for both quality and quantity MP Tool Meet drawing


Required MP MP MP process, sequence, and cycle time


of origin

MP associate (all shifts)

MP final location

Global Part Maturation Definitions

Process Material Manpower Build

Location Maturation

Level Description Tool Equipment

FixtureJig/Testing

Device

• If part cannot meet noted criteria above, please notify Honda (Q/D section in delivery plant) to discuss acceptance.• Exceptions:

• Hot Stamping--- T2/ T3/ LT: Laser blank allowed• Wire Harness --- T2: MP equip for cut, crimp, splice; Temp equip for assembly board only• Piping / Tubing --- MP Bender not required until T3

Part Approval Requirements

HSQM-0027 Page 1/5 04/01/2019

Purpose Part Approval is the Honda decision that the supplier can consistently produce a quality part that meets the CBU requirements, and the part can be used in mass production. It applies to new and changed parts for new model.

Responsibility Honda is responsible to establish the part and/or process requirements and review

them with the supplier. The supplier is required to ensure parts meet the drawing and specification requirements and to provide evidence that the process meets requirements.

Timing

Each project establishes timing for suppliers’ PA-2, PA-3, PA-4.1/4.2, and PA-5 submissions. Suppliers are notified of timing, at each project kick-off.

Timing Description PA-2 Evaluation/milestone prior to die GO PA-3 Evaluation/milestone prior to New Model Events

PA-4.1/4.2 Evaluation/milestone during New Model Events PA-5 Evaluation/milestone prior to Mass Production

Part Rank Honda assigns a rank to each part (A, B, or C). The rank is determined by quality

(drawing rank, part complexity factors, supplier factors, and supplier QD performance factors).


Exact submittal timing is project dependent. Requirements are given to suppliers as early as possible. The table below shows the timing for requirement submittals.


HSQM-0027 Page 2/5 04/01/2019

Part Approval Requirements (cont.) O = required A = where applicable U = upon request Honda Requirements for New Model Part Approval

Item

Rank PA-2

(at NMR 2) PA-3

(at NMR 3) PA-4.1

(at NMR 4-1)

PA-4.2

(at NMR4-2) PA-5

(at NMR 5) Part Approval

A B C

1. PV Testing A A A

• Supplier submits initial plan • Supplier identifies/ justifies/ submits Surrogate Data (if applicable) • Honda feedback concerns

• Supplier / Honda finalize plan • Supplier submits Risk Analysis (if applicable) • Honda confirms plan

• Supplier / Honda confirm testing started & D/C impact • Supplier submits Risk Analysis (if applicable)

• All testing is complete and test summary submitted (Pass/Fail) • Supplier submits Risk Analysis (if applicable)

• Supplier submits formal report • Honda / Supplier confirm report • Supplier submits Risk Analysis (if applicable)

Test results approved

2. Certification / Government Regulation

A A A • Honda identifies all certification requirements by region

• Supplier establishes certification plan

• Supplier / Honda confirm cert. activities on schedule per plan

• Supplier / Honda confirm cert activities on schedule • Supplier confirms and submits part marking, data and report to Honda

• Certification Test results approved and/or certification complete

3. PACV A A A

• Honda issues Initial Form • Supplier updates and submits Initial Form

• Supplier submits Phase 1 • Honda confirms Phase 1

Honda updates suppliers with new PPH

Honda updates suppliers with new PPH

• Supplier submits completed Phase 2 • Honda confirms Phase 2

• PACV Phase 2 complete

4. PFMEA O U U • Supplier submits draft • Supplier / Honda review

• Supplier updates & submits • Supplier / Honda review

• Supplier updates & submits

• PFMEA updated & reviewed

5. PQCT O O U • Supplier submits draft • Supplier / Honda review

• Supplier updates & submits

• Supplier updates & submits • Supplier complete process audit (Honda may request results) • Honda may perform audit

• PQCT updated & reviewed • PQCT process audit complete

6. Traceability & Lot Control

A A A • Honda notifies Supplier of applicable LNDD requirements

• Supplier returns LNDD• Honda reviews LNDD

• Honda approves LNDD• Supplier submits PDF (for 1:1 traceability parts)

• LNDD approved

7. Part Accuracy & Process Capability

A A A

• Supplier submits draft IDS • Supplier / Honda review • Honda identifies critical measurement points for capability study

• Supplier updates & submits • Honda confirms IDS • Honda / Supplier finalize critical measurement points for cap. study • Honda identifies if 100% part layout required

• Supplier / Honda confirm latest event data • Supplier / Honda confirm capability study results • Supplier / Honda confirm part layout results • Supplier c/m's accuracy concerns

• Data Sheet confirmed • Capability study results meet requirements • Part layout results meet requirement • Accuracy concern items c/m'd

8. Inspection Fixture

A A A

• Supplier submits concept • Honda approves concept

• Supplier completes gage certification & submits approval form (excluding Gage R)

• Supplier completes Gage R & submits approval form • Honda approves fixture

• Insp fixture approved

9. Design Change (D/C) Level

O O O • Honda / Supplier

confirm correct D/C level applied

• Correct D/C level confirmed

10. Event Problems

A A A • Supplier c/m's event

problems • Event problem items c/m'd

Minimum Requirements for Interim Part Approval

If any of the above items are not complete at Part Approval timing, path forward must be reviewed with the Honda Quality Representative (e.g. PV Risk Assessment, Temporary Countermeasure for quality issue, etc.) If deemed acceptable, Honda Management will issue Interim Part Approval until all requirements are completed.


HSQM-0027 Page 3/5 04/01/2019

Part Approval Requirements (cont.) O = required A = where applicable U = upon request ADDITIONAL REQUIREMENTS (Applicable parts, submission requirements and timing are project/plant dependent)

Item

Rank PA-2

(at NMR 2) PA-3

(at NMR 3) PA-4.1/4.2

(at NMR 4-1/4-2) PA-5

(at NMR 5) S&A

B C

11. TPR A A A New model project to set requirements

12. 3A Audit(Frame) QAV(Engine)

A A A New model project to set requirements

13. Material Analysis Report

U U U New model project to set requirements

14. Post Durability Test Part Analysis (Zenbara)


15. Texture / SpeCla A A A New model project to set requirements, also refer to NMR: Texture/SpeCla section

16. Color / Textile A A A New model project to set requirements, also refer to NMR: Color/Textile section

17. Appearance, Illumi, Feeling Masters

A A A New model project to set requirements, also refer to NMR: Appearance, Illumination, Feeling Master section

18. Limit Samples (Frame) PQS(Engine)


19. MPR U U U New model project to set requirements, also refer to NMR: PQCT, Label and Sub-Supplier Readiness sections

20. Sub-Supplier Approval

U U U New model project to set requirements, also refer to NMR: Sub-Supplier Readiness section

Definitions The supplier completes the following, as required by Honda, for each part approval. For additional

details, reference the individual procedures in this manual or the NMR documents.

Item Description

PART APPROVAL REQUIREMENTS

PV Testing Refer to HSQM PV Testing section for details

Certification / Government Regulation Refer to HSQM Data section for details, partial reference

PACV Refer to HSQM PACV section for details

PFMEA Refer to HSQM PFMEA section for details

PQCT Refer to HSQM PQCT section for details

Traceability & Lot Control Refer to HSQM Traceability and Lot Control section for details

Part Accuracy & Process Capability Refer to HSQM Data section for details For 100% Layout Requests: Measurement confirmation of all drawing features on Honda drawing. Honda to clarify applicable parts & quantity to be measured.

Inspection Fixture Refer to HSQM Inspection Fixture section for details

D/C Level Part is at correct D/C level and meets latest specification to meet Mass Production requirements

Event Problems

• All part related problems (at supplier, receiving inspection, QSSs, etc.) that are not acceptable for CBU approval identified through a Trouble Report / PTC process must be countermeasured • Must be a permanent C/M • CBU specific problems found during NM trial events • Problems must have C/M with affect to CBU explained • No “negative” impact to CBU quality


HSQM-0027 Page 4/5 04/01/2019

Item Description

ADDITIONAL REQUIREMENTS (PROJECT AND/OR PLANT DEPENDANT)

TPR Refer to HSQM TPR section for details

QAV / QAV-2

Process or method for conducting a process audit. Uses: • 2-hour / 200-piece trial; “run-at-rate” • Mass production associates, performing processes per operation standards, on a mass

production ready line (process) • Review of line-side documentation • Review of supplier internal audit results • Review of mass production equipment, tooling, jigs, and/or fixtures • Quality parts – meeting applicable tolerances / specifications

Material Analysis Report A report that explains the tests/analysis performed and test results for change points to material or processing of new model change parts. Typically requested for engine parts but may also be requested for some frame parts.

Post Durability Test Part Analysis (Zenbara)

Dyno and CBU post-test parts sent back to supplier for analysis. Typically requested for engine parts but may also be requested for some frame parts.

Texture / Specla Refer to HSQM Specla section for details

Color / Textile Any part with color or textiles judged visually to master and CBU harmony The supplier prepares data and/or samples confirming each appearance item per project requirements

Appearance, Illumi, Feeling Masters Refer to HSQM Master Sample Development section for details

Limit Samples (Frame) PQS (Engine)

Limit Samples: Refer to HSQM Limit Sample section for details (Frame) PQS: Honda may also issue a Part Quality Standard (also known as a Quality Agreement) to the supplier to clarify specifications. This may be done when: • The specification is not shown on the drawing • The specification is shown but needs clarified • The specification needs slight modification • Honda needs to specify a part identification marking

MPR • Requirements mandatory for applicable manufacturing processes documents available upon request • Refer to HSQM MPR section for details

Sub-Supplier Approval

Supplier's system used to confirm and approve their sub-supplier parts, processes, and material changes prior to mass production start up timing. This system must incorporate requirements ensuring that the parts meet drawing and specification requirements. Evidence of this approval system is to be summarized with supporting documentation, and made available to Honda prior to QAN approval, for purchased parts. Normally this is submitted at the QAV-3, if one is needed.

Important Notes

The supplier is 100% responsible for all documents, regardless of part rank The supplier conducts internal QAVs prior to each Honda QAV Honda to decide where applicable, if additional requirements/changes to the

above matrix are necessary


HSQM-0027 Page 5/5 04/01/2019

Approval When all Honda part approval requirements are met and reviews are satisfactorily completed, the authorized Honda associate issues a part approval to the supplier. The supplier is then permitted to ship parts for mass production.

Interim Approval

In the event parts are needed for production of sellable units, and the approval items are only partially complete, an interim approval can be issued. Interim approval can only be given in the following situations: Portions of the requirements for final approval are incomplete The complete portions are satisfactory The incomplete portions have a completion plan And the incomplete portions do not cause significant risk relating to quality or

delivery OR

Portions of the requirements for final approval are unsatisfactory but can be

made satisfactory by some temporary expediency (e.g. handwork) In this case the interim approval is conditional upon the continuation of the

expediency and upon a plan to obtain final approval

Process Failure Mode and Effect Analysis (PFMEA)

HSQM-0018 Page 1/2 04/01/2015

Guidelines & Development

The Process Failure Mode and Effect Analysis (PFMEA) systematically examines the production process for a part, determines potential failures and establishes priorities for instituting preventative actions to avoid or detect the failures. PFMEAs are a standard tool in the automotive industry. Honda North America has adopted the Automotive Industry Action Group (AIAG) guidelines, method, format and rankings (Severity, Occurrence & Detection). Refer to latest revision of Potential Failure Mode Effect & Analysis Manual at www.aiag.org for development instructions and the standard form. Honda specific requirements, which are written as “customer requirements” in the AIAG manual are outlined below. Also note that while AIAG refers to APQP and PPAP, Honda utilizes NMR and Part Approval process.

Honda Requirements

As stated in AIAG’s manual, customer (Honda) requirements are to be included in the PFMEA process. Examples include but are not limited to: New Model, Before Tooling GO: PAC-V items – past problem history items from HTR, MIR, Warranty, etc. Control points related to new technologies Minimum Process Requirements

New Model, After Tooling GO: Design Change – include new potential failures from change points Development concerns – issues that arise during new model development should be

reflected into PFMEA (testing, maturation, etc.) Trial Event concerns – issues that arise during new model trial events should be reflected

into PFMEA Mass Production: Design Change – part of IPPAAR process HTR, MIR – include failure modes from actual issues General:

• Suppliers must have systems in place to periodically review FMEA’s for the purpose of:

• Implementing corrective actions per Honda’s request • Continuous improvement on higher severity failure modes • Adding failure modes not previously identified

• Honda may require corrective actions if • After Process review, controls are not deemed acceptable • RPN values ≥ 130.

Process Failure Mode and Effect Analysis (PFMEA)

HSQM-0018 Page 2/2 04/01/2015

Submission Requirements

New Model: Submission requirements (scope & timing) details are in the Part Approval section of this manual. Typical scope is parts that: are S or A rank, have PAC-V requirements, have regulatory or certification requirements, new technology, etc. Mass Production: Updates may be requested as part of IPPAAR requirements, design change confirmation, HTR/MIR reflection, etc. General: Although Honda’s requirements are detailed above, suppliers are encouraged to create PFMEAs for all parts to optimize process design.

Proprietary Content

If any information on the PFMEA is deemed by the supplier and/or Honda to be proprietary, the copy provided to Honda for review and reference is stamped with the word “proprietary” in the appropriate place(s) on the PFMEA. Suppliers may be concerned with confidentiality when providing Honda complete details of their proprietary process. In this case the supplier may provide partial detail of the completed PFMEA. The supplier develops the complete PFMEA and maintains at its facility. Honda is permitted an opportunity to review the document at the supplier’s facility or during meetings at Honda.

Revisions Note – Honda may, at any time, request a copy of the most recent revision for review.

Process Quality Control Table (PQCT)

HSQM-0021 Page 1/3 04/01/2019

Background The PQCT outlines the overall control plan for producing the specified part. It is based on the idea that consistent quality comes from a consistently (controlled) process. It provides an accurate description of the process and defines the control method for manufacturing conditions and quality characteristics for each item requiring quality control

Requirements The supplier must create and maintain a PQCT for each process used in

manufacturing parts supplied to Honda Each final assembly part supplied to Honda requires a PQCT Component PQCTs may also be required Honda may require a PQCT to be submitted for review Honda is permitted to keep a copy of each PQCT for reference

Identical Processes

If two or more part numbers have identical processes (e.g. left and right side parts) One PQCT may cover all part numbers List each applicable part number on the PQCT

Similar Processes and Component Parts

If two or more part numbers have substantially similar processes and component parts One PQCT may cover all part numbers List each applicable part number on the PQCT Indicate differences within the appropriate sections of the PQCT

Format Use of the Honda PQCT form is encouraged. Any alternate form used must

contain all information on the Honda form. Honda must approve the alternate form, prior to use. AIAG standard formats may be submitted so long as supplemental information is attached for any Honda uniquely required information (e.g. PQCT table I).


HSQM-0021 Page 2/3 04/01/2019

Proprietary Information

If any information required to be on the PQCT is deemed by the supplier and Honda to be proprietary, the copy provided to Honda has the word "proprietary" in the appropriate places on the PQCT. The supplier retains an original PQCT with all required information and Honda has access to that original during QAVs to the supplier. Suppliers may be concerned with confidentiality when providing Honda complete details of their proprietary process. In this case the supplier may provide partial detail of the completed PQCT. The supplier develops the complete PQCT and maintains at its facility. Honda is permitted an opportunity to review the document at the supplier’s facility or during meetings at Honda.

Approval Revisions

Before a completed PQCT is submitted to Honda for review, it is approved according to the supplier's internal approval procedure. It is expected that the approval come from the quality manager or equivalent. This applies to new and revised PQCTs.

The supplier is responsible to maintain the PQCT as an accurate description of the current process. The supplier notifies Honda when a change occurs in the process flow, component or material source, quality characteristic control or manufacturing method / condition control and follows the necessary steps in the Change Point Control procedure in this manual.

PQCT Notification or Submittal Timing

The table below shows PQCT notification/submittal timing.

PQCT Type Timing Confirmation Items

New Model Part Approval (Draft PQCT) PA-3 Review of PQCT Table I and II Adequate controls

Communicate concerns New Model Part Approval

(Updated PQCT) PA-4, PA-5

Supplier ensures PQCT matches process Process audit review with PQCT PQCT review only (document review) Confirm PQCT control points are properly

reflected in job operation standards Mass Production IPPAAR

Change in process flow Change in component or material source Change in quality characteristics Change in mass production process or controls

Design Change HTR/MIR/NMR follow up actions

As Required

Confirm adequate controls and completeness for change point items


HSQM-0021 Page 3/3 04/01/2019

PQCT Completeness

Confirm the following are included Process flow charts and BOM All processes including but are not limited to Receiving Handling and storage of components Processing (assembly, welding, coating etc.) In-line and off-line testing and inspection In-line and off-line repair Quality audits (inspection, measurement and testing) Packaging Labeling

PPH items are included in control items details Process Assurance Capability Verification (PAC-V) Sheet Items Predicted failure modes from the PFMEA & DFMEA or FTA that

require process control FMEA “Failure Modes” are in general PQCT “Product Characteristics” FMEA “Causes” are in general PQCT “Process Characteristics”

Manufacturing Quality Standard items Inspection Standard, as applicable Drawing Q-points, critical control points MPR requirements, as applicable Regulation requirements, as applicable Lot control requirements, as applicable

Inspection Fixture

HSQM-0049 Page 1/19 06/01/2012

Background This guideline is intended as a reference for all fixtures used to assure the quality of parts purchased by Honda. It is intended to produce accurate and consistent quality inspections of Honda parts, regardless of the fixture supplier or manufacturing method.

Fixture Types The fixture types included here are

Holding (CMM, height gage, etc.) Attribute (Go/No Go) Variable Body / mating part simulation

Timing

New Model Timing Timing Purpose Requirements

PA-2 Supplier submits concept Honda approves concept

Supplier issues drawing concept to indicate how a part is held/measured on a fixture

Supplier submits Supplier Inspection Fixture Concept Form to NM/PQ

NM/PQ reviews and reaches agreement with supplier on fixture concept

PA-3 Supplier completes Gage

Certification

Supplier completes Certification requirements Supplier completes & submits Supplier Inspection

Approval Form to NM/PQ, excluding the Gage R

PA-4 Supplier completes Gage R

& submits Approval Form Honda approves fixture

Supplier updates & submits Supplier Inspection Approval Form to NM/PQ, including Gage R

Design Guidelines Holding

A simple fixture with little or no complex math data that holds and locates a part by using the part's datum and nets. Measurements cannot be conducted without the use of measurement equipment (CMM, height gage, etc.) (see figure 1).

Figure 1

Inspection Fixture

HSQM-0049 Page 2/19 06/01/2012

Attribute (Go/No Go)

A fixture designed by using complex math data. The material is undercut to allow for gap and flushness checks. Datum and net surfaces are used to control part fit and location. Data is collected using various measurement devices (stab pins, scales, taper gages, and go/no go pins) (see figure 2). All lines and surfaces used for part measurement are clearly identified and painted accordingly. O (zero) gap or flushness - Red 1mm gap or flushness - Green 2mm gap or flushness - Blue 3mm gap or flushness - Yellow 5mm gap or flushness - White

Figure 2

Inspection Fixture

HSQM-0049 Page 3/19 06/01/2012

Variable A fixture designed using complex math data. The material is undercut to allow for gap and flushness checks. Datum and net surfaces are used to control part fit and location. Data is collected using various electronic measurement devices.

Example - gap and flushness check using L.M.I. 770 and 200 gages (see figure 3).

Figure 3

Example - surface check using L.M.I. 200 gage and digital indicator (see figure 4).

Figure 4

Flush

Gap

Inspection Fixture

HSQM-0049 Page 4/19 06/01/2012

Variable (continued)

Example - SPC two axis check (hole) - Tru-position probe and mounting block (see figure 5).

Figure 5 Example - SPC third axis check (hole) - Tru-position probe block with third axis gage and L.M.I. 200

(see figure 6).

Figure 6

Inspection Fixture

HSQM-0049 Page 5/19 06/01/2012

Body Simulation

A fixture designed using mating part complex math data. The material is cut to nominal mating part data to evaluate the fitting between parts. This can be combined with Attribute and/or Variable data collection by making removable check blocks.

Design Layout Requirements

The design layout requirements are listed below. Data sheets and the Honda issued drawing shall be used for the

determination of all datum, nets and check points. The fixture base will be parallel to the X-T, Y-B or Z-H plane of the

vehicle. The lead engineer determines base orientation. Recommended materials

Steel - any non-datum surface shall be painted or rust proofed. Datum surfaces must be oxidized

Aluminum - any non-datum surface shall be painted or anodized. Datum surfaces must be anodized.

Carbon Fiber Planking material (e.g. DP-1051) or equivalent Any other material must be approved by Honda and/or the supplier

All contour template checks specified shall be 6.35mm stock - SAE

1018. All sharp edges shall be removed. Locating points are clearly identified (i.e. datum, locating holes or nets). All fixtures are required to have datum labels clearly identified. Labels

must show T, B and H direction values. If datum features cannot be labeled directly, the values may appear on a plaque affixed to the fixture base (see figure 7).

Datum Identified by Plaque Datum Identified Directly

TBH Fixture Datum T 100 B 100 H 100

Figure 7

Inspection Fixture

HSQM-0049 Page 6/19 06/01/2012

Design Layout Requirements (continued)

All sight checks shall be a minimum of 3.0mm and a maximum of 5.0mm clear from part surface with a minimum depth of 3.0mm. Sight checks shall be made to virtual nominal with scribe (see figure 8).

Figure 8

All holes with a positional tolerance of +/- 0.5mm or less shall be pin checked for location unless otherwise specified.

For a threaded hole pin, use minor diameter of thread minus location

tolerance for the pin size. Length of pin shall be equal to projected tolerance zone specified on the part model (see figure 9).

Figure 9

Min 3 Max 5 Min 3

Pin size – tolerance of hole location

Part Surface

Weld Nut

Inspection Fixture

HSQM-0049 Page 7/19 06/01/2012


Hand gages shall be designed as small and light as possible. Weight for hand gages shall not exceed 25 pounds for one operator and 60 pounds for two operators. The total weight shall be calculated and indicated on the stock list.

For hole measurements required on the bottom side, the part shall be a

minimum of 175 mm above the base when using the Tru-Position probe (see figure 10).

Figure 10

Keep brackets below checking area whenever possible. SPC bushings shall be verified to math data. SPC bushings shall have heads and press fit, unless specified otherwise.

H

B

175mm

Inspection Fixture

HSQM-0049 Page 8/19 06/01/2012


LMI flush and feeler blocks shall be mounted normal/parallel to all features checked (see figure 11).

Figure 11

Flush checks shall have a minimum of 25.0mm flush surface where possible (see figure 12).

Figure 12

Flush check point

3.0mm feeler check

24.0 mm

19.0mm set-up

LMI 776 block

LMI 770-G Flush & Gap Gage

Center of locating dowel

Gage block

Part

Inspection Fixture

HSQM-0049 Page 9/19 06/01/2012

Adequate protective safety devices shall be provided for protection of personnel and equipment, including stops for drop assemblies and clamps.

Add scribe lines with values as specified. All scribe lines are to be used

only as reference features not as datum features. Fastening and storage shall be provided and required for all loose details

when not in use on the gage. Design Layout Requirements (continued)

Large fabrications shall be made with welded tubing that has a minimum wall thickness of 1/8" (3.175mm), unless otherwise specified, and shall be normalized.

All removable details shall be secured to the gage and stamped with the

tool number. Paint the model identification color on all unfinished areas excluding

base plate surface. (Honda Model Specifications) Black oxide all steel check details (i.e. nets and pins). All lettering on

black oxide details shall be white. Paint all non-check elements on hand apply fixtures. Paint all clamp handles yellow on complex fixtures with multiple part

sets. All lines and surfaces used for part measurement shall be clearly

identified and painted accordingly. Identification code shall be stamped on all gages

O (zero) gap or flushness - Red 1mm gap or flushness - Green 2mm gap or flushness - Blue 3mm gap or flushness - Yellow 5mm gap or flushness - White

All gages which have multiple model check features shall be clearly

identified by model color, per Honda Model Specifications. Stamp gage pin diameter on all gage pins.

Inspection Fixture

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Operation Description Sheets

Operation Description Sheets (ODS) describe the initial set-up of the checking fixture, the loading of the part, the sequence of the clamping operation and the clear instructions for all feature inspections. ODS requirements are listed below. The ODS shall be plastic laminated and attached to the base. The ODS will have the correct clamping sequence as determined by the

GR study. Clamps shall be stamped, using brass tags fastened with screws, sequentially in the order of the closing sequence.

All transducer checks and their number are shown. Usage of any removable details is clarified.

Design Status Design status reports are required on a weekly basis. The report is made to

Honda and/or the supplier. Reporting percentage milestone criteria 10% - order placed - supplier has part information and job has been

started 25% - design ready for review and approval - job is laid out and material

is being ordered 50% - design is ready for final review, complete - buy-off and ship to

build source 100% - construction is complete including any build changes - archived

at Honda, buy-off and ship

Inspection Fixture

HSQM-0049 Page 11/19 06/01/2012

Base Plates Base plate requirements are listed below. Stamp body coordinates on the base per start dimensions (i.e. line

grooves, blocks and tooling balls). The base shall be sized so that all clamps and targets do not overhang the

periphery of the base when in the open position. Also, there shall be sufficient surface provided on the base for mounting interchangeable tooling and inspection equipment.

The base height surface shall be 30 inches from the floor unless specified

otherwise. Machined surfaces of bases shall be rustproofed. Floor bases shall have provisions for leveling (base pads or leveling

screws). The material for cast aluminum bases shall be SAE 315 or equivalent,

with Brinell hardness of 74. The average yield strength shall be 26,000 PSI and a tensile strength of 35,000 PSI. The supplier shall furnish the pattern.

All bases shall be machined on two adjacent edges. All steel bases shall be stress relieved. All aluminum bases shall be normalized. Bases shall be flat within +/- 0.1mm per square foot of area. The supplier shall provide swivel clevis type eyebolts at the four corners

if the fixture is heavier than 60 pounds. Eyebolts must have the load capacity to lift maximum weight of the

fixture plus 25%. Eyebolt size shall be determined by maximum load of eyebolt at a 60-degree pull.

Use helicoil screw locks for aluminum bases.

Inspection Fixture

HSQM-0049 Page 12/19 06/01/2012

Fixture Datum The fixture datum requirements are listed below. Note: Scribes lines are not to be used for fixture datum’s Option 1: Tooling balls (3) can be used for fixture alignment. The tooling ball shall be 12.0mm diameter with a 6.0mm diameter shaft;

press fit with a cover (see figure 13).

The centerline of tooling ball (X-T, Y-B, Z-H location) shall be stamped on the base.

Figure 13

Option 2:

Grooves can be used and must be clearly identified on the base (see figure 14).

Figure 14

Datum targets for Z Plane if top surface used for plane

Inspection Fixture

HSQM-0049 Page 13/19 06/01/2012

Fixture Datum (continued)

Option 3: Three planes can be used and must be clearly identified on the base.

Intersection corner shall be chamfered at 45 degrees (see figure 15).

Figure 15

Part Location Datum and Nets

The part location datum and net requirements are listed below. All four-way and two-way location pins shall use RFS pin locators,

unless otherwise specified (see figure 16). Wrong Way Right Way

Figure 16

All location pins shall have a hardness level of 52~56 Rockwell. All datum net surfaces shall have a steel grade of 1018.

PartRFS pin

PartRFS pin

15 ~20 Degree angle

Chamfered corner

B datum

H datum

T datum

Datum targets for Z Plane if top surface used for plane

Inspection Fixture

HSQM-0049 Page 14/19 06/01/2012

Part Location Datum and Nets (continued)

All two-way locators shall have RFS locators on slide units, unless otherwise specified.

Feature Shape Location Tolerance Part Datum’s Spring loaded RFS pins Location (+/-0.05) pitch (+/0.1) Net Surfaces Flat Surface Tol.(+/-0.05) Surface Templates Surface profile Location (+/-0.1) Stab Pins Location (+/-0.1) Tru-Position Blocks Location (+/-0.1) (X,Y,Z) (T,B,H) SPC Port Check location (+/-0.01) (position location +/-

0.2) 770 Block Check location (+/-0.01) (position location +/-

0.2) Tru- Position block 2 and 4 way locators

Pin Diameter (-0.1)

Clamping The clamping requirements are listed below.

Toggle clamping shall be 90 degrees to surface of material and attached

to the datum unit (see figure 17).

Figure 17

Ball Tip

Net Surface

Part

Inspection Fixture

HSQM-0049 Page 15/19 06/01/2012

Clamping (continued)

All clamps shall be inside the edge of the base when in the open position. To minimize base size, if clamp does overhang the base in full open position provide a stop pin.

The clamp contact point shall be centered to the net block. Stops shall be added when required to prevent pinch points. All clamps shall have ball spring plunger or steel swivel stops. No

rubber stops unless otherwise specified. Clamp locations and quantity should be correlated with Honda to prevent

excessive part distortion or constraint.

Hinge Drops and Swings

The hinge drop and swing requirements are listed below. Provide hydraulic stops for all gates, slides, clamps, gage bars, targets,

drop templates, etc. - in retracted position. All hinged dropped templates shall use steel T pins with bushing, unless

otherwise specified.

Slides The slide requirements are listed below.

The gage supplier shall determine slide type and style that will meet the

requirements for detail. Straight line accuracy Load Gage life Acting force Axial play

The gage supplier shall review slide rail specifications with Honda and/or

the supplier prior to final design completion. All slide units shall be self-cleaning.

Inspection Fixture

HSQM-0049 Page 16/19 06/01/2012

Slides (continued)

The gage supplier shall place slide unit as close to detail as possible (see figure 18).

Figure 18

Check Detail Check Detail

Slide Unit

Slide Unit

Riser

Riser

Base Base

(Preferred mounting of detail) T- Pin and bushing

T- Pin and bushing

Stopper

Stopper

Inspection Fixture

HSQM-0049 Page 17/19 06/01/2012

Certification The certification requirements are listed below. The inspector will certify that the gage has been built dimensionally

correct within acceptable tolerances and design change levels. The gage supplier shall have the following information available upon

certification Updated Supplier Inspection Fixture Concept form Certification Inspection data A road map showing the location of the inspection points Identification numbers on gage correlating to certification data.

The certification inspection data and the road map will be included and

shipped with the gage. All gages shall have a tag with the required information mounted to the

base plate (gage supplier name, part number/numbers, and design change level and certification date).

Gage R Study A Gage R study is an expedient method of demonstrating a measure of gage repeatability. It shall be performed at the gage construction source. In a Gage R study, one operator measures the same part ten (10) times. Calculations for repeatability are then performed and analyzed. Honda and/or the supplier shall provide the part/assembly to the gage build supplier to conduct the Gage R study. The gage build supplier shall notify Honda and/or the supplier prior to conducting the study.

Inspection Fixture

HSQM-0049 Page 18/19 06/01/2012

Gage R Requirements

The Gage R requirements are listed below. All gages shall be inspected, data verified and certified prior to a Gage R

study. The Gage R study shall be performed by the gage supplier and approved

by Honda and/or the supplier prior to shipment to the user plant. Inspection points used in the Gage R study are to be approved/supplied

by Honda or the supplier. Clamping sequence shall be determined and documented on the ODS. The Gage R procedure is

Load part according to the operation description sheet (ODS). The part shall rest on all net blocks. Adjust points of interference. Note and eliminate.

The clamping sequence is noted and followed according to the ODS. Optional clamp sequence requires experimentation and may differ depending on the application. The clamping sequence shall be the same for all ten trials.

The measurement process is repeated ten (10) times.

Buy-off Upon completion of the gage the following must be presented

Certification data Gage R study ODS sheets Completed Supplier Inspection Fixture form

Inspection Fixture

HSQM-0049 Page 19/19 06/01/2012

Shipping The shipping requirements are listed below. Gage jack screws and leveling plates shall be secured to the base for

storage during transit. Wooden containers are required for all small to medium size gages. All

large gages (e.g. aperture, floor pan, hood, etc.) shall be skidded, lubricated and wrapped in a waterproof protective covering.

A plastic envelope shall be permanently attached to the fixture. The

envelope shall contain the following information Certification data Gage R study ODS sheets Completed Supplier Inspection Fixture Concept form

This documentation shall be part of the gage record at all times.

Process Assurance Capability Verification (PAC-V)

HSQM-0094 Page 1/2 04/01/18

Background The Process Assurance Capability Verification (PAC-V) sheet, issued by Honda, is used to ensure identified critical control points (CCP) have appropriate process controls planned prior to tooling go timing and actual process capability and parts are confirmed prior to Mass Production. Evaluation of the actual parts and process controls is achieved by reviewing the current process / part data and recalculating the Process Failure Mode Effect Analysis Risk Priority Number (RPN) and confirming its effectiveness.

Scope The scope of the PAC-V is divided into three steps that cover the development

timeframe of a New Model project. Each project team defines specific parts application and deadlines for the following phases. (PAC-V type analysis may be performed at other times as directed by Honda.)

Purpose For Critical Control Points identified

- Assure part shows capability in NM through PFMEA analysis - Assure capability is maintained and monitored throughout Mass Production

through PFMEA analysis, PQCT control, and Operation Standards.

Timing Purpose Requirements

Initial Phase (complete

prior to Die-GO)

PA-2

Honda issues Initial Form with Supplier input

Understand the critical control points through – - Past problem history (NARS reports including MIR reports) - Manufacturing Quality Standards - Drawing and Specification study - The Technical Part Review process - Government Regulations

Supplier updates & submits Initial Form

For each Critical Control Point identified: - List prevention and detection control methods for each critical

control point. - Confirm the planned process controls are effective to prevent

recurrence.

Phase 1 PA-3

Supplier Submits Phase 1

Honda confirms Phase 1

For each Critical Control Point identified: - List quality and manufacturing control methods for each

critical control point. (shall be the same as the Process Quality Control Table controls and reflected into supplier operation standards)

Phase 2 PA-5

Supplier submits completed Phase 2

Honda confirms Phase 2

- Confirm the actual condition of parts and processes (at the Run-at-Rate (2hr/ 200 piece trial) or other trial representative of MP conditions, Honda may participate)

- Recalculate the PFMEA RPN using actual process and part data (attribute or variable)

- Recommended actions shall be agreed upon to countermeasure any identified concerns (occurrence and detection)

- Operation Standards, PQCT and PFMEA shall be updated to reflect final processes


HSQM-0094 Page 2/2 04/01/18

Targets

For Critical Control Points identified

PFMEA (Initial and Phase 2) o For controls that appear to be ineffective: can tooling, process, or

design be modified to reduce occurrence value of PFMEA. If so, Supplier change tooling, process, or design. May require CRF.

o Otherwise Supplier to increase process controls to reduce detection value of PFMEA

o Severity cannot be reduced through process changes, only through a vehicle system design change

PQCT (Phase 1 and 2) o Must clearly show manufacturing and quality controls as stated in

the PFMEA o Must show how the control point is to be monitored in Mass

Production and controlled in the operation standards Product Manufacturing Capability (Phase 2 only)

o Supplier to provide data at each New Model event for all CCP’s o PpK > 1.33 (If 1.33 cannot be met, Honda must evaluate the

recommended action and understand the revised PFMEA RPN ranking)

o Attribute data may be utilized and reviewed where appropriate After each PACV submission (Initial, Phase 1, Phase 2), Honda will review.

If any concerns/gaps are identified they need to be addressed.

Technical Part Review

HSQM-0052

06/01/2012

Background The Technical Part Review is an enhanced version of the part maturation process. The target for these reviews are to reduce the amount of market claims that have resulted from the plant and supplier not properly identifying the critical control points from the designer’s perspective. The overall concept is to identify all of the critical control points from the design and confirm they have been guaranteed through the supplier’s process quality control plan. This can be confirmed through capability studies, poka-yokes in place, QA equipment, etc.

Scope The scope of the Technical Part Review is divided into three phases that cover the development timeframe of a new model project.

No. Phase Who Objective

1

Design and Process Planning Review

Honda Plant Quality, Supplier, R&D and other support groups

• Understand the technology – parts and processes • Identify part and process change points • Review past problem history (PPH) items • Understand critical part/CBU characteristics • Identify critical control points • Develop process control plan

2 Process Maturation

• Verify critical control points • Participate in tool/equipment trials

3

Process Verification and Stabilization

• Confirm parts meet specification • Confirm process capability • Investigate and summarize path forward for any

non-confirming product produced • Verify process stability • Feedback/countermeasure market concerns

Part Selection Honda’s new model management team selects the parts that are evaluated. Part selection is based on, but not limited to the following criteria:

• New model part rank • New supplier to Honda • New technology/feature

• New material • New manufacturing process • New system

• High warranty • Supplier black box design

Suppliers are notified at the beginning of the project if their parts are selected for a technical part review.

Technical Part Review

HSQM-0052

06/01/2012

Timing and Reviews

At the beginning of each project, the Honda new model team reviews the project schedule and determines the timing for the three phases, and when each review will occur. The Technical Part Review timing aligns with and feeds into the supplier’s New Model Review (NMR). A document detailing part number(s) and Technical Part Review specifics for the project will be sent to suppliers selected for TPR activity.

General Activity Details

The following table may be used as a general guideline for new model development activities applied to a part selected for TPR.

TPR Phase

1 2 3

Design & Process Planning Review Process Maturation Process Verification & Stabilization

Cat

egor

y

Des

ign

Stu

dy/P

art

Acc

urac

y

• Review part DCS, part concept or data/drawing for change points and concerns

• Review past development history • Design/usage intent • CCPs & datum structure • Review/Submit CRFs as needed • Inspection fixture concept review

• Review design changes and CRFs made since TPR-1

• Confirm D/C tracking • Update CCPs as needed based on any

change points • Review event part accuracy • Confirm inspection fixture meets

requirements

• Review design changes made since TPR-2

• Review trial event data and part approval

• Confirm inspection fixture meets requirements

• Determine MP readiness

Pro

cess

D

evel

opm

ent

• DFMEA/FTA > PFMEA correlation • Confirm appropriate equipment

controls are planned • Review PACV/PPH items • Confirm sub-supplier development

requirements and strategy • Trial event process and part data plan

• All concerns that could not be designed out have process controls in place

• PQCT complete & ready for use • Confirm PACV items • Trial event data requirements are

clear • Sub-supplier development on track

• Confirm PACV results • Confirm PFMEA, PQCT, Operation

Standards, and Actual Process match • Confirm process readiness for MP • Review sub-supplier development

results

PV

Tes

t P

lan

• DV test status and results • PV test plan review • Joint testing plan in place

• Confirm plan still captures all requirements

• PV test status and timing review • Joint testing status and results

• Review PV test results, regulation items, certification reports

• If needed, confirm risk assessment details

• Joint testing results

Tra

ce-

abil

ity • Traceability expectations are clear

• Critical data for each process identified

• System requirements understood

• Traceability system in place • Control method meets requirements • LNDD complete

• Confirm traceability results

Limit Sample

HSQM-0037 Page 1/2 07/01/15

Background A limit sample is used for parts that cannot be measured or counted (e.g. appearance or items that have a judgment factor involved).

Two Sets For some parts, Honda may request a set to keep at Honda. When two sets of

limit samples are made for each part, they are as exact as possible to one another. The supplier shall, if duplicates of the limit sample are made, number the duplicates and control with a ledger. The supplier keeps one set, Honda keeps the other.

Agreement Both the supplier and Honda must agree on the limit sample. A

representative from the supplier and Honda approves each set.

Changes If for any reason the standard needs to be changed by the supplier or Honda,

new samples are made. The new samples are approved by a representative from the supplier and Honda

Limit Sample Tag

Limit sample parts are identified by a tag (label or tag attached by wire). The tag contains the following information. Part name Part number Effective period (the length of time the limit sample is good for) Appropriate supplier and Honda signatures, as required Brief description of the limit sample content Date of production of the limit sample Note - Limit Samples are controlled (e.g. by a control number), and the control is referenced on the PQCT.

Limit Sample

HSQM-0037 Page 2/2 07/01/15

Example Tags

The supplier or Honda may furnish the limit sample tag. The figures below show example tags. These are examples only.

LIMIT SAMPLE

Part Name

Part Number

Effective Period

Honda Supplier

Content

Master Sample Development

HSQM-0055 Page 1/2 07/13/07

Master Samples Illumination master sample development involves those parts with lighting in

high visibility areas, such as radio displays, headlights and speedometer displays.

Feeling master samples involve those parts that are operated by the customer, such as outlets, buttons, switches, and handles.

Other masters may also be developed.

Approval Although specifications provide direction, evaluation of actual parts is necessary to verify the parts meet the design intent. The approval process of master samples varies from project to project, depending on who is responsible for the design – Honda Research and Development North America – Ohio (HRA-O) or Honda Research and Development Tochigi Center (HGT). However, the general schedule is the same.

In addition to confirming individual parts, parts are installed on a completed body unit (CBU) and evaluated. The intent of the design is for all parts with the same specification to have the same illumination or feeling – when one part is compared to another part. For example, the LCD (liquid control display) on the radio display should match the LCD on the speedometer – or the left vent feeling as compared to the right vent.

Once all parts have been developed to the correct level of illumination or feeling, a vehicle evaluation is conducted to confirm the overall performance.

Difference Between Limit and Master Sample

A Master Sample is the target part the supplier aims for when producing each piece. It is a confirmation of design intent. A Limit Sample shows the range of allowable tolerances for production parts. It is a confirmation of the process.

Master Sample Development

HSQM-0055 Page 2/2 07/13/07

Type

Flow The chart below shows the approval flow for design masters.

Initial Drawing

PEDD Make parts list from drawings and Honda CRF requests

Initial Drawing Purchasing Match to maker layout

and tooling

Type

JA U1 SU SU SJ SJ P/T (pass-thru)

Make responsibility and prioritization list to coordinate master creation with R&D, stylist and supplier U1 - SU PEDD JA - P/T Japan Purchasing JA - SJ Japan Purchasing JA - SU PEDD

HRA/HGT Sign-off

(sign-off is done at evaluation by

R&D, PEDD and Supplier)

HRA/HGT (CBU) evaluation with HRA, VQD, NMS/PQS

and PEDD

“PEDD Coordinates”

Supplier makes master sample from MP tooling. When spec

criteria is met, issue for review.

HRA/HGT oversees supplier activity

PEDD Receive master from HRA/HGT and submits to NMS / PQS and Supplier

Supplier compares master/specification to MP

parts and adjusts “NMS/PQS oversees supplier

activity”

VQD Honda CBU evaluation with VQD, PQ and PEDD

Approve MP Parts

No Yes

Does MP part match master / specification and is quality

OK?

New Model Receiving Inspection

Purpose To confirm that purchased parts used for Honda new model trial events meet delivery and quality requirements.

Scope This procedure applies to all parts used for new model applications.

Responsibility The supplier is responsible to ensure that the new model parts meet the correct design change level, delivery, and quality requirements as set forth by Honda. Honda will notify suppliers of detailed request for each project. Request may include data, maturation information, labeling and identification method, etc. Honda is responsible for the review of parts for the new model event. See the flow chart below which describes the process flow.

Non- conforming Parts

Honda expects all parts to meet drawing and new model event requirements. Do not ship any non-conforming part without prior authorization.

RECEIVING INSPECTION WORKFLOW SUPPLIER HONDA

Supplier may be required to send a Pre-Inspection data sheet to show inclusion of CCP's

START

Honda places New Model Event order

+ Basic event timing and requirements are set by the Q/D project leader at the beginning of the project.

Supplier builds NM Event parts and takes part data

NO

PE/AQ Judge OK to use ?

NO Designated Honda associate

notified. Each site will handle through standard non-conforming part procedure.

Supplier completes

receiving inspection form, collects part

data/accuracy information

Part D/C matches expected

D/C level?

YES

N/G

Any parts that deviate from expected design level, that are not within specification, require authorization prior to shipment.

Parts arrive at inspection location

(Honda plant or warehouse)

Honda associate

confirms actual part design change level

Honda associate reviews supplier inspection data for the event

Honda associate

reviews parts and makes part quality

judgment

Part quality judgment?

OK

Complete

HSQM-0036 Page 1/1 11/01/10

Surface Finish

HSQM-0075 Page 1/4 04/01/2019

Purpose Develop tooling that will be used to manufacture appearance parts

Scope Outline the steps required to input essential information and track status of

appearance part tooling maturation.

IS this a Surface Finish part?

End of ProcessNo

Complete steps 1‐4

Does this part

require texture?

Yes

No End of Process

Yes

Complete steps 5‐8 End of Process

Forms Appearance Part Tooling Detail (APTD)

Texture Indication Map (TIM).

Reference Document

Minimum Tooling Specifications for Surface Finish Parts.

Surface Finish

HSQM-0075 Page 2/4 04/01/2019

Step 1 Honda will determine the list of Surface Finish parts.

Step 2 For each designated Surface Finish part, the supplier must adhere to the

Minimum Tooling Specifications for tooling development. Deviations from the Minimum Tooling Specifications must be negotiated with Honda.

Step 3 Determine if Honda part will require an APTD Form

Thedrawingand/orHondawilldetermineifpartisaSurfaceFinishPartthatwillrequirethesuppliertofilloutanAPTD.

a) IfNo–ProcessCompleteb) IfYes–Supplier/Hondamustcompletetheprocedureand

workflowforappearancepartdevelopment.SubmitAPTDDocumenttoHonda.

Step 4 AppearancePartToolingDetail(APTD)Completion

HondanotifiesthesupplierofSurfaceFinishpartsthatrequireanAPTD.ThesuppliercompletestheAPTDasrequiredandsubmitstoHondanolaterthantheduedate.HondaqualityrepreviewstheAPTDfortherequiredcontentandeitheracceptsorrejectsthedocument.

Accept:Ifthedocumentisaccepted,theHondaQualityRepwillsignthedocumentandnotifythesupplier

Reject:Ifthedocumentisrejected,itwillbereturnedtothesupplierwiththeconcernsoutlined.ThesupplierisresponsibletoupdatethedocumentwiththerequiredchangesandresubmittoHondawithin3workingdays.

___________________________________________________________________________________________

Step 5 Determine if part will require texture The drawing and / or Honda will determine if part is a texture part.

a.) If No – Process complete

b.) If Yes – Supplier / Honda must complete the procedure and

workflow for texture development

Surface Finish

HSQM-0075 Page 3/4 04/01/2019

Step 6

Texture Indication Map Completion Honda notifies the suppliers of texture parts that require a

TextureIndication Map (TIM)

The supplier completes the TIM as required and submits to Honda no later than the due date. Grain orientation is dictated by Honda.

Honda Quality Rep reviews the TIM for the required content and either accepts or rejects.TIM

Accept: If the document is accepted, the Honda Quality Rep will notify the supplier. Reject: If the document is rejected, it will be returned with the concerns outlined and the supplier is responsible to update with the required changes and re-submit to Honda no later than 3 days from the document being rejected.

ThesupplierprovidesaT‐3levelpartandTIMtothespecifiedtexturesource.ThetexturesourcewillfillinthedetailoftheTIMandmarktheT‐3partwithgraindepthanddirectionperthesurfaceconditiondrawingor3DAnnotation,anddraftanalysis.TheTIMandmarkedpartarereviewedandapprovedbyHonda,supplierandtexturesourceindicatingagreementwithcontentofmapandmarkedpart.

Step 7

Texture Go - A T3 part is submitted to Honda to be reviewed for Texture Go. Accept: Honda notifies the supplier the part has texture go. The signed / approved TIM for“Texture Go” is sent to the tier 1 part who then facilitates the tool texture activity.

Reject: If the T3 part is rejected, the Honda Quality Rep. notifies the supplier with the concern items. The supplier must submit another part with the concerns counter measured to meet the required MP quality maturation level

Surface Finish

HSQM-0075 Page 4/4 04/01/2019

Step 8

Texture Approval – The tool is textured and sample parts are run at rate in the mass production equipment / location. The supplier will submit a T4 Level partfor each cavity for texture approval by Honda Quality rep. The part will also be reviewed at the CBU color / texture / gloss harmony review meeting with Honda Styling associate at Honda Specified event timing.

Accept: If the T4 part is acceptable, then the Honda Quality Rep. will notify the supplier that their part has texture approval with a signed TIM

The approved texture map is sent to the supplier and a copy is put into the part file. Reject: If the T4 part is rejected, the Honda Quality Rep. notifies the supplier with the concern items. The supplier must submit another improved part with the concerns items counter measured to meet the required MP quality maturation level

Note Honda sites may require additional detail.

Minimum Tooling Specifications for Surface Finish Parts

HSQM-0054 Page 1/3 04/01/2019


The following tooling development requirements are mandatory for manufacturing tools for Surface Finish parts. The purpose of this requirement is to ensure the tool surface accurately represents Honda styling data.

1. Material Receiving Inspection

Inspection Item

Method Inspection Frequency

Tool Material Confirmation

• The supplier and the tool shop are required to make sure that the material used to manufacture the tool is confirmed to meet material specified for the tool and that they have traceability (e.g.: material certification).

• Supplier must guarantee die/mold material meets or

exceeds Honda’s requirements for quality/quantity during the designated duration of the project.

Prior to Machining

2. Equipment Item Method Frequency

Machines used to manufacture tools for Surface Finish parts

Accuracy that can reproduce the required surface data in the tool and stay within the required machining requirement for scallop height, chordal deviation and cutter path steps.

Prior to Machining

Software used to manufacture tools for Surface Finish parts

Software used for translating data, designing tooling, and generating machining instructions for equipment are required to be at a level that can reproduce the actual surface data in the tooling. Allowances made for tooling offset and clearances may be required to produce a part that meets Honda requirements.

Prior to Machining


HSQM-0054 Page 2/3 04/01/2019

3. Process Controls

Item Requirement Frequency

The maximum scallop height requirement on cavity/electrode final cut appearance surface shall not exceed 0.005mm.

Scallop Height

Cutter Cusp of Scallop

0.005 mm Max.

Throughout the final cutting process

Finished Cavity/Electrode surface

The chordal deviation allowable shall not exceed 0.005mm on the finished surface of the cavity/electrode. There is to be no visible faceting allowed on the cavity appearance surface.

Chordal Deviation

PT1

PT2

Chordal Deviation 0.005mm Max

PT3 PT4

PT5

PT6 PT7

During the set-up of software used to generate the cutter paths on the machining center

Points used to generate the cutters path over a contoured surface are specified to be spaced so as not exceed the 0.005mm Chordal Deviation

The maximum step between cutter paths or EDM/cutter paths allowable shall not exceed 0.010mm from the finished surface of the cavity/electrode final cut/burn on appearance surfaces.

Step Between Machined Surfaces/ Electrical Discharge Machining

(EDM) Surfaces

Cutter path 1 Cutter path 2

Finished Tool surface 0.010 mm Max.

SEC A-A

Throughout the final cutting/EDM process

Cutter path 1 Cutter path 2

A A


HSQM-0054 Page 3/3 04/01/2019

3. Process Controls (continued)

Item Requirement Frequency

Maximum Cutter Radius

The maximum radius of a cutter must be smaller than the minimum radius of the area to be cut to ensure that there is no cutter chatter in this area.

During tool programming and

set-up

Cutter Paths

The cutter paths must reproduce the actual surface data in the tooling. Tooling is to have no additional handwork other than necessary polishing of machine marks within the specifications in regards to scallop and cutter path steps.

During tool programming and

set-up

Gate type and location

If not specified by the drawing, the gating type and location on the part must be negotiated between the supplier and the responsible Honda Plant.

During the Drawing review

Tool Welding

No tool welding is to be performed on any visual surfaces without first informing Honda. All welding on visual surfaces must be a full process weld with proper color match (Laser/Micro weld exceptions). Note: All weld locations must be identified to the texture shop before texturing.

Prior to any welding

4. In Process Inspection Item Method Frequency

Dimensional Confirmation

The supplier is responsible for dimensional accuracy of tooling. Honda may request data confirmation of tooling if necessary.

After tool is complete

5. Quality Confirmation

Inspection Item

Method Inspection Frequency

Visual Surface Confirmation

Honda reserves the right to inspect all tools for Surface Finish parts. All requested tooling cavities and electrodes are inspected prior to any polishing. Any tooling that deviates from the requirements of this procedure may be requested to be re-cut at no cost to Honda, and with no effect to the part delivery schedule or the required

Prior to polishing of the visual

surfaces, or as negotiated with

Honda.

Gloss Meter Correlation Requirements

HSQM-0077 Page 1/2 04/01/2019

Purpose This document defines the flow to conduct the gloss meter correlation process. When the specification, “Spec, Interior Part Gloss” (0094Z-SFA-9000), is indicated on the part drawing, suppliers are required to complete the correlation of their gloss meters.

Scope This document applies to all North American Honda manufacturing facilities and

their North American Tier-1 suppliers.

Procedure Supplier is responsible to identify gloss meter correlation requirements through

review of drawing and specification information.

Supplier submits gloss meter to North American Purchasing, NA SQD Color Group for correlation study.

Suppliers are recommended to contact NA SQD Color Group prior to sending gloss meter, so that NA SQD is aware that equipment is being sent or delivered and that the supplier is not without equipment for extended period of time. (Typical turnaround time is one business day.)

Gloss meters shall be delivered to NA SQD Color Group by: Hand carry by supplier Overnight delivery (UPS, FedEx, etc.) Deliver to:

Honda of America Mfg., Inc. Marysville Material Center (MMC) 24000 Honda Parkway Marysville, OH 43040

Attn: NA SQD Color Group Phone: (937) 644-7805

If equipment is sent by overnight delivery, contact name, phone number and

email address shall be included with equipment, in case information is needed when correlation procedure is being completed.

All records are stored within the NA SQD Color Group’s “Gloss Meter

Correlation Database.” NA SQD Color Group issues a Correlation Report to supplier when equipment is

returned (see example next page). Supplier shall provide their Honda Purchasing New Model and/or Mass Production Representative a copy of the report, if requested.

Gloss Meter Correlation Requirements

HSQM-0077 Page 2/2 04/01/2019

DATE:

Gloss reading from master correlation gloss plaque, using 60 o angle.

Spec 1st Reading 2nd Reading 3rd Reading AverageA 1.7 1.8 1.7 1.73 1.8 1.8 1.7 1.77B 1.9 1.8 1.9 1.87 1.9 1.9 2.0 1.93C 2.4 2.4 2.5 2.43 2.4 2.4 2.5 2.43

Constant value results, determined by above data

(slope) A = 1.07(intercept) B = -0.20

Formula to use for converting gloss meter reading to reported readings

Suppliers converted values to report to Honda

Reporting Value

Supplier Value

Reporting Value

Supplier Value

Reporting Value

0.9 1.7 1.6 2.4 2.4

1.0 1.8 1.7 2.5 2.5

1.1 1.9 1.8 2.6 2.6

1.2 2.0 1.9 2.7 2.7

1.3 2.1 2.0 2.8 2.8

1.4 2.2 2.2 2.9 2.9

1.5 2.3 2.3 3.0 3.0

Comments

“Spec, Interior Parts Gloss” (0094Z-SFA-9000).

NAT Associate SignatureThursday, March 20, 2008

Sec

tion

A

Supplier Name: Great SupplierSupplier Number: 123456

Gloss Meter Maker:

Se

ctio

n B

Sec

tion HGW values

BYK-GardnerGloss Meter Model: micro-TRI-gloss

Gloss Meter Serial #: 986369 Joe DoeLast Calibration Date: 3/18/08 Contact Number: 123-456-7890

Supplier Contact Name:

Sec

tion

CS

ectio

n D

y = Ax + Bx = gloss meter reading, y = actual gloss value, A & B = constant values

1.5

1.6

Readings from supplier gloss meterAverage of

HGW values

Max Hue

Sec

tion

F

Thanks

Sec

tion

E

Supplier Value

1.0

1.1

1.2

1.3

1.4

Traceability and Lot Control __________________________________________________________________________________

HSQM-0028 1/8 04/01/2019

Purpose Traceability and lot control require identification of the component parts for Honda

products, so that if any problems occur due to those component parts, it can be traced, isolated, contained and corrected. Honda requires all parts to conform to the appropriate level of lot control, as determined by Honda.

Lot Control Levels

There are three levels of lot control.

Level of Control

Description

One to One

Each individual part has a unique identifying number or code. All WIP lot information is retained and WIP container is linked to 1:1 barcode. All sub component/WIP lot information and mfg test results are tied into 1:1 barcode. 1:1 link between part label and container label. Each part is directly linked to a Honda EIN, PSN or VIN.

Lot Range Each group of parts has a unique identifying number or code that links to the supplier’s manufactured lot number. Each group of parts is directly linked to a group of Honda EIN, PSN, or VIN.

General Each group of parts has a unique identifying number or code that links to the suppliers manufactured lot number. Each group of parts may be directly linked to a Honda EIN, PSN, or VIN.

Type Control

Level Document Required

Supplier Shipping Control – Minimum Requirements

Enhanced Traceability

One to One PDF and LNDD

Lot Range LNDD

Basic Traceability

General N/A

Manufacturing Lot Number

Individual Part – Bar Code or

Other

EDI Container Label – Box

Serial Number

Advance Ship Notice (ASN)

Ship Date

Must link these items

Must link these items

Manufacturing Lot Number

EDI Container Label – Box

Serial Number

Advance Ship Notice (ASN)

Ship Date


HSQM-0028 2/8 04/01/2019

Notification Timing

Honda provides digital notification to the supplier when parts require control above the minimum (General) level. The notification normally occurs early in the part development process. A notification form or email is sent to the supplier to identify the parts that require control and the level of control.

Lot Number Display Detail (LNDD) Form

The LNDD form displays the location of the supplier’s manufacturing lot number, or other information that Honda links to the EIN, PSN or VIN. Refer to the LNDD operation standard in this manual.

Displaying the Lot Number

Unless specified by Honda, the format and method of displaying the lot number is proposed by the supplier and approved by Honda. This is accomplished using the LNDD form. If the lot number is to be displayed on the part, Honda and the supplier consider the effect on quality and the ease in which the mark can be seen on a completed vehicle. Honda encourages placing lot number markings directly on the part. This can be used during an inspection and initial analysis. All parts that are bar coded must meet Honda Bar Code Standards. General Level Parts Unless specified by the drawing or otherwise by Honda, the format and method of displaying the lot number is determined by the supplier. All Parts All parts, regardless of the control level, require the supplier’s manufactured lot number to be identified in relationship to the EDI container label, and linked to the ASN. PQCTs reflect key lot control requirements shown below.

Process Display Form (PDF)

The purpose of the Process Display Form (PDF) is to illustrate the traceability of manufacturing process conditions, components and characteristics through each step of the process flow. The PDF is completed by the supplier for parts that require one to one enhanced traceability. This form also shows how the information is retained and linked to the next process and details of traceable quantities. The supplier uses this as a method to identify potential lot control/traceability concerns. Once the concerns are identified, the supplier works to implement countermeasures. Refer to the PDF operation standard in this manual. The PDF is submitted to Honda at least one month prior to the mass production ready QAV. The PDF is re-submitted to Honda when the process is changed. Note - Suppliers may use the PDF internally, even if they do not have one-to-one control level parts.


HSQM-0028 3/8 04/01/2019

Special Requirement for SRS LNDDs

SRS parts have a one to one level of lot control. Those parts have a bar code lot number, which is scanned in Honda's production departments. HM NMC dictates the bar code format for SRS parts. Linear bar code must conform to JIS X0503 or ANSI Code 39 Data Matrix 2D bar code must conform to ISO / IEC 15415. QR 2D bar code must conform to ISO / IEC 18004.

(see the bar code procedure in this manual) The bar code must not exceed the maximum numbers of digits established

by the Honda production facility.

The bar code format should start with Part Code (1 digit) and Derivation Code (3 digit), followed by the unique Manufacturing Serial Number, shown below. The remaining digits can be used at the supplier’s discretion.

Part Code Derivation Code Manufacturing Serial Number Supplier Optional*

Each bar code must be unique, duplication is not permitted Spaces are discouraged as one of the digits A major design change to the part may require a bar code change Part Code - dictated by Honda - tells part type (e.g. seat, cable reel, side

sensor) Derivation Code - dictated by Honda - tells model, application and

supplier (e.g. -S84-A100 Supplier A) Manufacturing Serial Number - the supplier assigns a unique serial

number to each part produced Supplier Optional - these digits are optional for the supplier's use.

However, once format has been agreed upon, changes cannot be made without Honda approval.

Determining Lot Size

Lot size maximum should be limited to product produced within one shift. When determining lot size, much thought needs to be put into how it will be controlled process to process. Suppliers must also consider the impact to themselves and

1 3 4 2


HSQM-0028 4/8 04/01/2019

Honda, in the event of a part concern. Smaller lot sizes are encouraged, and may be directed by Honda. Lot size is reviewed during development to ensure that it meets Honda’s requirement. If it exceeds the maximum one shift, a countermeasure will be required.

Controlling Lots

To have good lot control/traceability, suppliers must control lots process to process. Lot control and change point control is crucial in determining suspect lot information. Poor control adds to the quantity of product impacting the customer. Supplier internal systems must be capable of promoting all Honda key requirements. Key Requirements FIFO throughout each process 100% accountability for all relative data pertaining to the formed manufactured

lot as show in Illustration 1 below. 100% accountability for all change point information within a manufactured lot. All relative data is linked to the timely disposition of repair parts within the same

manufactured lot Records and traceability of component parts and materials used in each step of the

manufacturing process Records and traceability of manufacturing conditions in each step of the

manufacturing process (e.g. torque, pressure, oven temperature, etc.) Parts are not mixed when traveling from process to process

Illustration 1


HSQM-0028 5/8 04/01/2019

Sub-Supplier Requirements

Tier One suppliers are responsible for all sub-supplier’s lot control/traceability. Sub-supplier’s lot control/traceability is periodically audited by and clearly understood by the Tier One Supplier. Tier One Suppliers must ensure that the Sub-supplier’s procedures are established in a method that enables lot control/traceability information to be easily obtained.

DSPS/JSP Requirements

Product lot control level is assigned to DSPS/JSP product in the same manner as Tier One suppliers. DSPS/JSP suppliers are required to link the DSPS/JSP product to a final unit or range of product being produced. DSPS/JSP lot information to be recorded by the Tier One Supplier will be provided by Honda during New Model development. Product linkage can only be determined by the receiving supplier. DSPS/JSP suppliers are required to follow procedures as directed by Honda.

Retain all relative data

pertaining to the formed

manufactured lot

Mixed LotParts

IPP Change Points

Changes in Inspection / Equipment

Material Data

Component Lot

Information

Prod. Date / Shift /

Associates

Abnormal Situation / Repair Logs

Mfg Method / Condition


HSQM-0028 6/8 04/01/2019

Re-worked Product Requirements

All product is required to have traceable lot control information available that is linked to the product being shipped. Product removed from the normal process must maintain traceable lot control. Suppliers are required to clearly identify and understand how this is accomplished in their facility (e.g. documenting in procedures). Suppliers periodically audit to assure compliance.

Repack Requirements

All manufactured lot information for parts that are repacked by the supplier must be maintained and linked to the new container EDI label.

Shipping Lot Control Minimum Requirements

EDI/ASN Requirements EDI container labels are required on each container/for each part number Must know all manufactured lot/change point information in relationship to each

EDI container Must add a human readable manufactured lot number on each EDI container label Link the manufactured lot number to all EDI container serial numbers associated

with an ASN by recording the applicable manufactured lot number into the ASN field provided

Key Point Some Honda plants may require the Honda production lot number to be entered into the ASN manufacturing lot field instead of the supplier’s manufactured lot number – or in addition to. If the supplier is to only use the Honda production lot number, the supplier must retain records that show the supplier’s linkage to their manufactured lot information. See Illustration 2 on next page.

Shipping Lot Control Minimum Requirements (continued) Illustration 2


HSQM-0028 7/8 04/01/2019

Requirement Link Supplier's Manufactured Lot Control Number to Each

Part / Container

Requirement Two Common

Container Labels per Container

Each EDI Label Serial Number is Unique

Ship Product to Consolidation Center or Required Location

PART NO EXT(C)

SERIAL(1S)

PART NO.(P) 71570-SV4 -A000-AA-01

YR169LDESCRIPTION

12345678-12345678

QUANTITY(Q) 1000000

XYZ COMP ANY, 100 S BLOOM ST. , COLUMBUS, OH 43221

1996 ACCORD ABS RR BUMPER(TI#)

D/C PART LEVEL(2P) 00-AA-01

*P71570SV4 A000AA01*

*CYR169L*

*2P00AA01*

*1S1234567812345678*

*Q1000000*

PART #SPLR

AUDITMFG.DATE

Requirement Must add a human

readable manufactured lot number on Each

Part / Container with


HSQM-0028 8/8 04/01/2019

Mixed Manufactured Lots

Containers that hold parts from multiple manufactured lot numbers are limited as much as possible

Those containers must have a manufactured lot number assigned from the supplier that links to all individual manufactured lot numbers within the container

The assigned manufactured lot number must be displayed on the EDI part container label. That number must also be in the ASN

If the product has enhanced traceability requirements, that container may need to be identified visually. Visual method to be negotiated between each Honda plant and the supplier. Visual methods may vary from Honda plant to Honda plant.

Rejection of Unacceptable Lots

Honda reserves the right to reject any shipment, or portion of a shipment, not meeting the requirements of this procedure.

Product Validation (PV) Testing

HSQM-0033 Page 1/9 04/01/19

Background Product Validation (PV) testing is required by Honda for a supplier to demonstrate the mass production processes produce a part that meets or exceeds the minimum testing requirements.

Requirement Honda Quality and the supplier negotiate which parts require testing based on

drawing specifications, HES, and other requirements. PV Testing must be completed for all listed specifications to validate a part during New Model development. Honda may require additional parts for testing. The supplier must provide requested parts to Honda. Part dimensional data for test parts must be obtained and archived by the supplier. When PV Testing is required during mass production, parts must be reconfirmed to the specifications. In addition, an IPPAAR must be submitted by following Honda’s Change Point Control procedure. The supplier can request the use of surrogate data. This request is submitted in writing with a detailed technical explanation of the tests being proposed to be omitted and the reason for omission. These requests are negotiated and judged between the individual Honda plant and the supplier on a case-by-case basis. If a test is approved to be omitted, the technical explanation (with reason) is submitted with the PV draft plan as well as the final test data. Unless Honda approves the use of surrogate data, all test listed in specs, HES, etc. are required. Note - the supplier is responsible for all PV Testing regardless of lack of in-house lab or applicable CBU testing.

Timing The following table clarifies PV test requirements and establishes the

relationship between the new model development cycle and the product validation timeline. It is the supplier’s responsibility upon receipt of each D/C (this includes both NM timing major and minor model changes as well as D/Cs made during MP) to compare the change to the specification to ensure if new testing is needed.


HSQM-0033 Page 2/9 04/01/19

Timing (continued)

Timing Purpose Requirements

PA-2

• Supplier submits initial plan • Supplier identifies/ justifies/

submits Surrogate Data (if applicable)

• Honda feedback concerns

• Confirm test items to drawing/specification requirements • Develop initial test plan • Submit surrogate data & justification if planning to use • Negotiate and determine test responsibilities • Confirm plan meets project requirements [Start at T3 maturation,

MP Material, complete by project requirements (PA-4.2 unless otherwise specified)]

• Identify potential concerns

PA-3

• Supplier / Honda negotiations complete

• Supplier submits Risk Analysis (if applicable)

• Honda confirms plan

• Revise test plan based on latest drawings, specifications and updated maturation schedules (check impact from any D/Cs)

• Confirm plan meets project requirements [Start at T3 maturation, MP Material, complete by project requirements (PA-4.2 unless otherwise specified)] Implement corrective action as needed (including Risk Analysis)

• Clarify test report format requirements • Test plan finalized, including aligning Testing Lab schedules, with

your planned part maturation timing

PA-4.1

• Supplier / Honda confirm start of testing and impact of design changes (D/Cs)

• Confirm testing starts, per plan • Parts(s) used in PV testing must be at a T3 part maturation

level, unless lower maturation is approved, by Honda • PV Testing must start, as soon as the required part maturation is

achieved • Include dimensional data, of part(s) used in testing • Monitor for D/Cs and schedule conflicts to ensure that PV

testing meets project requirements • Supplier must contact Honda immediately, if part has failed

during testing, or testing will not meet project requirements, in any manner

• Use Risk Analysis form to detail impact, of test completion date exceeding PA-4.2 due date, or failure of one or more test items

• Confirmation of supplier part certification has been completed, if applicable

PA-4.2 • Supplier / Honda confirm

completion of testing and results

• Confirm testing complete with summary results issued to Honda (pass/fail)

• All tests complete, and pass, per plan (pass to specification) • Use Risk Analysis form to detail impact, of test completion date

exceeding PA-4.2 due date, or failure of one or more test items

PA-5

• Supplier submit formal report

• Honda / Supplier confirm report

• Supplier submit Risk Analysis (if applicable)

• Submit final test report to Honda, with management signatures, and ensuring all tests are complete & passed

• Use Risk Analysis form to detail impact, of test completion date exceeding PA-4.2 due date, or failure of one or more test items


HSQM-0033 Page 3/9 04/01/19

Clarify Requirements

Honda test requirements are clarified with the supplier. The supplier uses the most recent drawings and specifications to develop a general test plan, incorporating the requirements.

Confirm Prior To Test Plan Development

The supplier and Honda review maturation requirements, test responsibilities, potential problems, and additional test requirements prior to developing a test plan. After establishing the test requirements and responsibilities, Honda Quality works with the supplier to develop a PV test plan. Items to be clarified before developing test plan include:

Item Primary

Responsibility Description

General Maturation Requirements

Honda Quality

With the supplier, Honda Quality – clarify part and process maturation of PV test samples, CBU maturation, and test completion requirements, monitor development schedules and business issues.

Test Responsibilities

Supplier Confirm part meets all drawing and specification requirements and government regulations. Provide data to support CBU requirements as requested. (Honda or R&D may support specialized part testing as needed.)

Honda

Verify PV test parts are at T3 maturation level or higher unless approved by Honda Quality. Honda Quality –act as the “window” for supplier part testing and part approval. PE – complete and approve CBU testing, specialized part testing and material applications.

R&D Approve design validation (DV) test results at the prototype level.

Potential Problems

All areas Identify any significant changes and/or past concerns related to design, manufacturing, materials, test procedures or the CBU that may create potential problems. Include corrective action as needed.

Additional Testing Requirements

Supplier and Honda

Supplier – identify additional requirements for mating parts, body unit or equivalent, and test equipment. Honda Quality – evaluate additional requirements, clarify cost related issues.

Develop Test Plan

The supplier proposes the initial test plan. Honda Quality evaluates the test plan. When establishing the test plan, the following items are considered, incorporating drawings and applicable specifications.


HSQM-0033 Page 4/9 04/01/19

Item Considerations

Maturation of Test Samples

Part maturation schedule matches test plan requirements. Parts at T3 or higher maturation level are available for testing. Mass production processes used in manufacturing of test samples.

Test Schedule

PV testing is started as soon as T3 parts are available and is complete by project requirements (PA-4.2 unless otherwise specified) Date for Honda receipt of test report included. Start and end dates for each test are established. Adequate recovery timing incorporated if retest required. Milestones established for long-term testing or concern items. Example: A 120-cycle test takes 3 months to complete. Milestones may be required at 40 and 80 cycles to confirm interim status.

Test Items

Test items include: (for Level 01 and child parts) Drawing notes Specification requirements Applicable HES, JIS, SAE, etc. Special requests from PETD or R&D - Note: Testing must be Honda specification testing, not FMVSS and not supplier specification testing (unless referenced in drawing or specification) Material certifications if specified on drawing PPA items and previous testing concerns - Example: Paint adhesion is a PPA item. Additional testing that exceeds specification may be required Part dimensional data is in spec for test parts.

Test Quantity

Required quantity of parts per test is a minimum of 3, unless otherwise agreed upon with Honda. Consider the following items: Part Variation (A000, E000 …) Test result variation Past test results history

Test Methods

Test methods are clearly understood. New supplier, new technology or new test requirement may need clarification of test methodology. Request PETD and R&D assistance as needed. Specialized test equipment/test service acquisition. Procurement of mating parts or body units for test requirements included in plan. Supplier coordinates through Honda Quality or PH.


HSQM-0033 Page 5/9 04/01/19

Review Special Considerations

Special situations may arise that require Honda Quality judgment. Special situations are reviewed before finalizing PV test requirements. If a component or part is carryover from a previous model, it may be possible to use previous test results as surrogate data if the following conditions apply: It is not possible for the New Model change point to affect the test results; the

supplier must provide explanations or evidence to support this conclusion. No changes have occurred to the parts, processes, materials or test

requirements since approval of the test results. All regulatory requirements are maintained

Example: flammability test Tested with plaque (dimensions carryover) Material and color carryover

In general, the surrogate data for any project must not be older than 3 years from the scheduled FMC (Full Model Change) start-up date (see Figure 1 below). Honda project management will communicate surrogate data age requirements through the FMC or MMC (Minor Model Change) project kick-off packet.

Although some test results may be carryover, the test results must be included in the submitted PV Test Report.

The PV Test Report should be able to stand alone with no reference to an earlier model.

Final judgment on the admissibility of previous test results for PV testing requirements will be determined by Honda Quality. Honda will accept data submitted at FMC on carryover parts and components for MMCs in that program until the next FMC.

Honda shall consider a part or component as a carryover part if it is indistinguishable from a part or component currently sold to Honda on another model in mass production.

It must be produced on the exact same (not similar) production line.

Production line must be in the same factory, in the same location, using mass production associates and mass production process sequence.

Both the mass production and new model parts production must use the same (not similar) equipment and tools.

Equipment must be set up to the same fixed parameters using the same controls, poka-yokes, jigs, and fixtures.

A previous model is any program, including all FMCs and subsequent minor model changes (MMCs), launched before the program in question.

A FMC (Full Model Change) is a new model program not derivative of a previous model year. FMCs typically occur every 5-6 years.


HSQM-0033 Page 6/9 04/01/19

Figure 1:


HSQM-0033 Page 7/9 04/01/19

Review Special Considerations (continued)

In special cases if PV test timing exceeds the allowed project timing, Honda

Quality may grant exception for the testing of a lower maturation part. If a part requires a Honda body or equivalent for PV Testing as stated in the

specification: 1. Supplier to review drawings/specifications and identify any part that

requires a body or equivalent to complete PV testing and notify Honda.

2. Honda to notify supplier by PA-2 if a white body will be provided 3. Supplier to determine test plan and submit to Honda at PA-2 timing.

a. For parts that will not have a white body provided, Supplier must:

i. Request to purchase a body from the Honda assembly plant through a purchase order

ii. Develop a fixture “equivalent” to do the testing 4. Requirements can be divided into three categories and actions are

summarized below:

Revise Requirements and Clarify Test Format

The test plan should be reevaluated adjusting for changes related to the latest drawings and specifications, and any updates to the maturation schedules. The test report format should be clarified at this time.

PV Test Report Format

Product validation test format includes :

Report Item Details To Include

Summary Page

Supplier name Honda part number, Honda part name, design change level Honda test specification number, design change level Judgment Signature and date of individuals performing, confirming, and approving test results Indexed test items Page numbering

A • Testing must be completed on an “actual” body unit • These units are supplied by Honda

B • Spec states that testing to be completed on an "actual" body unit or "equivalent" • Supplier may purchase unit or produce fixture

C • Spec does not require testing on an "actual" unit • Supplier should plan testing with fixture


HSQM-0033 Page 8/9 04/01/19

Test Report Format

Test item Test conditions and methods (reference specification section) Identify and label each test sample Test data results for each sample tested (# of parts) Comparative data for additional support as needed

o Design validation test results (prototype results) o Japan and/or US part test data

Judgment o Non-conforming conditions that may impact test results o Part maturation level discrepancies or special observations

Test Data Format

Unit of measure should be consistent with specification (e.g. Spec is in metric, results should not be in English units.)

Actual data per test method, not only judgment Graph results as needed Initial and final data, if required Actual tested samples available for review when possible and use photos for documentation

Material Certification

Material description, material number Certification date Material lot number Material specification Chemical composition, mechanical properties Cladding, plating, other surface treatments

Part Dimensional Data

Utilize agreed upon Inspection Data Sheet from PA submissions.

Child Parts Test results are provided if a specification exists. Format follows Level 1 part test results format. Testing Readiness

• Part dimensional data reviewed and accurate per spec. • Test maturation is T3 or higher (unless approved by Honda Quality) • Test spec and method is understood by testing party • Test schedule includes reporting milestones • Total PV test plan is agreed upon with Honda Quality (changes must be

communicated to Honda)

Begin Testing Complete Testing

Confirm testing has begun per the established test plan

Submit updated PV test plan indicating actual start date when testing begins. All test items must be completed according to the established test plan.


HSQM-0033 Page 9/9 04/01/19

Evaluate and Judge Results

At a minimum, the following items are considered when evaluating results: Verify actual test parts are per maturation plan, including tool level, design

change level, and documented Confirm test methods and conditions per specification Confirm test data per specification Evaluate actual test samples or photos, when possible Evaluate test data to comparative data, as needed Establish judgment (OK or No Good) Submit results to Honda Note – if part fails testing or testing is delayed and will not be complete by PA-4.2, the supplier must notify Honda immediately and submit Risk Analysis documentation and obtain approval from Honda.

Establish Corrective Action Plan

If results are not acceptable / marginal, additional analysis may be required to determine root cause of failure / seriousness of concern, and the corrective action required through a risk analysis report to Honda. The following items are included when establishing a corrective action plan:

CBU Impact Potential impact to vehicle / customer

Analysis

Variation Analysis Actual test samples including dimensional variation Impact, if any, from process variation Impact, if any, from test method variation Larger sample size from different production lots Comparative Analysis – test results Product validation to design validation Japan data to U.S. data Bench data to CBU data

Schedule Determine corrective action and re-test schedule, if re-testing cannot be completed by required timing (usually PP lot), inform project management

Supplier Evaluation

Upon test completion supplier must evaluate test results and determine judgment, according to the evaluation requirements listed above. Failed, incomplete, or other pending results require judgment by Honda.

PV Test Risk Analysis Form Guidelines

HSQM-0071 Page 1/2 04/01/2016

Purpose To provide notification to Honda that a supplier has experienced a delay or failure in Product Validation testing that does not meet Honda project requirements.

Scope This procedure applies to all parts that require Product Validation Testing.

Responsibility The supplier is responsible to notify Honda immediately in the event of PV test failure or delay. The supplier must complete a PV Test Risk Analysis form to identify testing status, submit a schedule for completion, and alternative options detailing the risks to Honda.

Procedure Refer to the following table:

PV Test Risk Analysis

Timing Purpose Requirements / Reportables Details Responsibility

PA3 / NMR3 or

immediately following a delay

or failure in testing.

PV Test Risk Analysis

-Project name, part name and number -Include reasons for test delay

-Include which spec items are complete / incomplete -Schedule for completion

-Start and finish dates - All alternatives explored to meet Honda Project targets

-Design Level

The Supplier issues the PV Test Risk Analysis Form to Honda to identify

risks that may be associated with late or failed PV testing and the activity

taking place to reduce / manage those risks.

Supplier

PA3 NMR3

Review Supplier Risk Analysis /

Honda judgment of revised test plan

-Confirm PV Test Risk Analysis is complete -Identify concerns and address with supplier -Evaluate Risk Analysis and summarize risk

-Honda management makes judgment

PV Test Risk Analysis is received from supplier. Honda reviews, assesses risk

and makes judgment.

Honda

PA4 / NMR 4

PV Test Risk Analysis weekly

status

- Weekly updates to Honda

- Plan vs Actual of Risk Analysis / Revised PV test Plan - Confirm testing is to plan - Provide interim results

-Confirm status for completion of all test items

Supplier issues a weekly status report of the PV Test Risk Analysis and PV

Test plan. The latest risk assessment, interim test results and completion

dates should be verified through the 3A principles.

Supplier

PA5 / NMR 5

PV Test Risk Analysis Results

- Updates to occur until testing is complete and judged OK - Complete past problem reflection of late test root cause - Root cause analysis and c/m to be shared with Honda - Countermeasures to be reflected into future projects

PV Test Risk Analysis Testing completed per Honda specifications.

Detailed reported issued to Honda with results and judgment. Results need to

be supported with proper documentation, data, sample parts and

photos.

Supplier

PV Test Risk Analysis Form Guidelines

HSQM-0071 Page 2/2 04/01/2016

PV Test Risk Analysis Workflow Honda Rep Supplier

Honda reviews Risk Analysis Form and

revised PV Test plan

Start

Supplier experiences delay in PV testing (e.g. scheduling / test failure /

incorrect D/C parts/ D/C impacts PV testing

and requires re-test)

OK per No Honda PL /

Mgmt review?

YYeess

Supplier completes Risk Analysis form

Supplier makes PV Test

plan adjustments

Discuss with supplier and

come to consensus for reporting plan vs actual

and interim test results until PV Test is complete

Supplier submits Risk Analysis Form and

modified PV test plan to Honda for review

Supplier implements revised PV Test Plan

Monitor plan vs actual and PV Test interim results until complete

2-way communication Report plan vs actual and Interim PV Test results until PV Test is complete


HSQM-0041 Page 1/11 04/01/2019

Background Over the life of a part or product, changes in design, specification or process will occur. The Initial Production Parts (IPP) system is used at Honda to approve and/or track changes to parts or processes. When the IPP system is used correctly Honda and suppliers have documented approval and accurate records of any change that occurs to parts or products. The IPP system helps to ensure final product quality by providing a way to identify, approve and control change points. This control is necessary to safeguard the quality of finished products.

Applies To The IPP system applies to all mass production parts, components and materials that are shipped to Honda that are part of a finished product. This includes each North American Honda facility and each Honda foreign destination.

Requirements The supplier's quality department is responsible for understanding the contents of any change and ensuring the change has no negative effect on the overall product quality. If a part is sent to more than one Honda plant, additional IPPAARs are required. The supplier must contact the Quality representative at each receiving plant to determine the requirement in each case. The supplier must receive approval from each plant. “A” level changes (see matrix) require approval in advance from Honda. The IPPAAR (Initial Production Parts Advance Approval Request) is the means used to obtain approval. An Initial Production Parts Quality Assurance Declaration must be filled out and attached to the IPPAAR on the Attachment tab in order for the IPPAAR to be approved. The Initial Production Parts Quality Assurance Declaration ensures that an OEM Company QA Representative, an OEM Facility QA Representative or Equivalent associate has reviewed all of the Quality characteristics, Parts Inspection Criteria, Part Approval, Chemical Substances, etc… and have evaluated the change point(s) and Declared that the changed parts meet all of the Quality Requirements. This Initial Production Parts Quality Assurance Declaration Form can be found in the SQM under the Forms tab. If the part is sent to more than one Honda plant, IPPAAR approvals from each plant are required. The supplier must contact the Quality representative at each receiving plant to determine the requirements in each case.


HSQM-0041 Page 2/11 04/01/2019

Changes Effecting Multiple Honda Plants

Use the following guidelines when processing IPPAARs for multiple Honda plants: 1. Supplier must organize change point details in written format including process, materials, supply chain flow, tooling, equipment, etc. 2. Supplier must create a detailed confirmation plan prior to contacting Honda. 3. Supplier must submit items 1 and 2 above with an invitation to a joint conference call / meeting with all affected plants. a) This allows Honda to consider the change and have internal discussions as needed prior to finalizing requirements and IPPAAR submission. b) Joint conference must establish a common set of IPPAAR requirements for change validation (testing, dimensional layout, etc.), risk mitigation (bank build), or other areas of common interest. c) Supplier must submit IPPAAR request with a confirmation plan including items decided in the joint conference.

4. Upon review of the official IPPAAR submission, plant PQs will add any items needed to verify impact to the plant or special model characteristics (packaging, delivery methods, unique CBU fit, assembly trials, etc.)


HSQM-0041 Page 3/11 04/01/2019

IPP Control Levels

There are three levels of control in the IPP process. They are listed in the table below. If you are unsure which level to use, contact your Quality representative.

Control Level Procedure Control Method

A - IPPAAR

The supplier initiating the IPPAAR must obtain PQ/PH approval prior to use in MP (use the IPPAAR form) The Initial Production Parts Quality Assurance Declaration form must be attached to the IPPAAR.

An IPP tag must accompany the first IPP parts for MP and the parts must be properly labeled

Note - IPP tags must apply to the first shipment that goes directly to Honda production. Do not send IPP tags with in-process parts.

Delivery of IPP parts must be done according to FIFO

The supplier must keep the following information

Date of IPP'd parts production

Date of delivery Quality confirmation

data such as inspection or testing data, if not attached to the IPPAAR

B - IPP Tag

Note - B level changes do not require an IPPAAR

unless instructed by Honda.

IPP tag must be attached to first IPP parts shipped

Note - IPP tags must apply to the first shipment that goes directly to Honda production. Do not send IPP tags with in-process parts.

Same steps as level A

C - Supplier Internal at the supplier The supplier tracks these changes. Information is made available to Honda upon request.

Use the following table to help determine the correct control level.


HSQM-0041 Page 4/11 04/01/2019

Types of Changes

It is necessary to issue IPP tags when there are changes to parts or processes that make those parts. The table below explains each change type, lists some example changes (change type not limited to examples), and how to determine the level of control (A, B or C). Note - a change in a part due to one of the listed types requires control of the first lot, whether the change originates internally or externally to the supplier.

No. Item Explanation/Examples A B C

1 Design Change

The part drawing changes, altering the physical structure of the part. A design change is done when a new part drawing or an M/I is issued. New part design Design change that affects the part

X

Design change that does not affect the physical structure of the part, such as part name or part number

X

2 New Supplier

A supplier or sub-supplier, who has never produced the part or component, begins manufacturing the part for Honda. Addition of a new supplier or sub-supplier Changing the supplier or sub-supplier New delivery location Change from in-house production to outside supplier (or vice versa) Change in factory location Substances of Concern (SOC) as per the SOC Manual.

X

3 Material Change

The material(s) used to manufacture the part is changed. Change of material supplier Material supplier changed from outside to self-supplied (or vice versa) Change in material composition (including anti-rust oil or lubrication oil) Substances of Concern (SOC) as per the SOC Manual.

X

4 Manufacturing Method Change

A process method, setting or condition used in manufacturing the part is changed or modified. This includes any change that effects the way the parts are produced as reflected in the PQCT. This applies when the normal control range changes, not for routine adjustments. Casting or forging method change Sintering condition change Heat treatment condition change Rubber or plastic molding condition change Welding condition change Plating or coating condition change Machining or cutting condition change Process standards or setting method change

Honda Quality Rep to

Set Level

Associate change on a critical process X


HSQM-0041 Page 5/11 04/01/2019

Types of Changes (continued)


5 Process Order

Change

The manufacturing process order is changed or deviates from the PQCT. Change to the order of the process, or adding or deleting process steps Change a temporary process to a permanent one (or vice versa) Note: If the IPPAAR process cannot be completed before parts are to be shipped (e.g. a welding robot breaks down and the process is done by hand) contact PQ/PH immediately. PQ/PH will provide instructions and requirements to suppliers in this situation


Set Level

6 Machine Change

When the machine initially used to produce the parts during the approval process has been changed or replaced by another machine. (Machine examples: stamping press, assembly line, injection or blow molding, forge press, etc.) Initial use of a new machine Major modification or repair of a machine Minor modification or repair of a machine Equipment relocation within the same plant Equipment relocation outside plant or building Changes to machine control logic (e.g. software upgrade or replacement

that affects machine function)


Set Level

7 Jig/Tool Change

The primary or secondary tooling or jigs are changed, potentially affecting the quality, function, appearance, or reliability of the part. (Jig and tool examples: welding or assembly fixtures used in manufacturing process, cooling fixtures, sonic or heat welding, etc.) Change in machining master for camshaft or pistons Change in machining master for other parts New or modified jigs and tools


Set Level

8 Die/Mold Change

A die or mold that is used in the manufacturing process is new or changed. New or renewed die or mold Revision or repair of the die or mold


Set Level

9 Inspection

Method Change

The inspection methods of the part are changed, potentially resulting in either an improvement or changes in the part’s quality performance. This may require a revision to the PQCT. New or modified inspection equipment Measuring method change or measuring instrument type change


Set Level

10 Transportation/

Packaging Change

The method of transporting the part to Honda, or the packaging of the part deviates from the initially approved method. The change could adversely effect the quality of the part. Change in delivery method, packaging materials or containers

X


HSQM-0041 Page 6/11 04/01/2019

Types of Changes (continued)


11 Use At Honda Direction Only

If directed to sort parts use the Sort Label Procedure HSQM-0067. In this case no actual IPP tag is sent and reason code (11) is entered into ASN along with HTR/DTR Number.

NA

An IPP tag may be requested if a sort is deemed critical. X

For all other instances, enter a detailed description in the How Changed area on the IPP Tag.

X

12 Weight Change Substances of Concern (SOC) as per the SOC Manual. X

13 Tariff The product source and/or source of materials included in the make-up of the product are changing as a result of Tariff laws. X

Note: A completed, approved IPPAAR form is required for all A level changes prior to shipment of the changed part. All IPPAARS must have an Initial Production Parts Quality Assurance Declaration form attached. All A level changes also require an IPP tag on the first production shipment to Honda.

Confirm Change

The supplier confirms the first lot conforms to all quality requirements before shipping. Confirmation data is retained by the supplier and may be required to be included with the first lot.

Identify the First Lot

The supplier identifies the first lot shipment with properly completed IPP tags. Shipments to multiple locations require an IPP tag for each Honda plant and production line. Parts of different colors require an IPP tag for each color. Suppliers must ensure that part/process changes are IPP'd for all Honda destinations.


HSQM-0041 Page 7/11 04/01/2019

Attach IPP Tag The supplier prepares the first lot for shipment by attaching a properly completed IPP tag in a conspicuous location. The first lot is shipped in FIFO order. Note – the IPP Tag must be printed on the canary yellow paper provided by Honda. Log into the HondaWeb Open the CPCS system (click on the CPCS Icon) and click on the ‘Help’ link in the upper right hand corner to open the CPCS training and view the “Ordering Paper Labels” page for ordering instructions.

Label the First Lot

The supplier clearly labels containers holding the first lot. Suppliers are required to use the labels described on the next page. Containers are labeled on the outside to show an IPP tag is enclosed. When a shipment contains both the first lot and older parts, all the containers in the shipment are labeled to indicate whether they contain old or new parts.

IPP Labels There are three IPP related labels. The table below describes each label.

Note – each label type is also available as a card with a wire. These are for instances where a label will not adhere to the container. Suppliers are to use the labels, instead of the cards, wherever possible.

Label Color Label Type Label Use

Pink IPP Enclosed In/On This Container To place on any container that holds an IPP tag

Green New Style Parts To place on all containers, in the IPP shipment, that are new style parts

Blue Old Style Parts To place on all containers, in the IPP shipment, that are old style parts

New Model Trial Events

Do not send IPP tags for new model trial events IPP tags are for saleable units only, when parts have changed Each project schedule identifies when saleable units begin Each project dictates how trial event parts are marked

Label Attachment

Follow these guidelines when attaching labels to containers. Wrap labels around opposite corners so they can be seen from all sides Do not cover any other labels with the IPP related labels (e.g. part number

or bar codes)


HSQM-0041 Page 8/11 04/01/2019

Labels wrapped around corner

IPP Notification via ASN

Suppliers must notify Honda concerning each shipment containing IPP related parts. The supplier must enter the IPP Tag number and the reason code into the ASN. For ASN information please refer to the “EDI Blue Book.” It can be found in the Honda Supply Team Portal on the reference tab under “EDI Barcode Info.” For sorted parts use the HTR/DTR number in the IPP Tag number field and reason code 11 as detailed in the Sort Label procedure (HSQM-0067).

IPPAAR Purpose

The IPPAAR form is used when a change requires advance approval from Honda prior to the supplier shipping the part for MP. Note - NM event part changes do not require an IPPAAR unless those units are saleable.

Number of IPPAARs

If a part is sent to more than one Honda plant, additional IPPAAR approvals are required. The supplier must contact the Quality representative at each receiving plant to determine the requirement(s) in each case. The supplier must receive approval from each plant. If a change affects similar parts/processes, it may be possible that several parts can be combined into one IPPAAR.


HSQM-0041 Page 9/11 04/01/2019

IPPAAR Flow The chart below shows the IPPAAR flow.

When the IPPAAR is created in CPCS, the system automatically creates IPP tags for the listed parts. Do not use those IPPAAR connected IPP tags for mass production line trials. Suppliers must create separate IPP tags for mass production line trials, indicating the appropriate IPPAAR Number/IPPAAR Tracking Number. Use the IPPAAR connected IPP tags with the initial mass production shipment.

All supplier issued IPPAARs and IPP Tags are created in the Change Point Control System (CPCS).

N/G Judgment

If N/G, Quality states the reason(s) and further action required

Supplier initiates/completes

IPPAAR information and submits to Quality at

each Honda plant affected

Quality reviews the IPPAAR and

negotiates with the supplier to finalize

approval requirements

The supplier produces samples, completes the requirements, updates quality documents and

submits to Quality along with the IPPAAR

The supplier completes

requirements and/or the

countermeasures and updates the

IPPAAR

Quality reviews the information and parts, marks a judgment and the IPPAAR is forwarded to the

supplier

The supplier produces parts for mass production

The supplier attaches IPP tags (generated from the IPPAAR) with the initial shipment of

changed parts

OK Judgment

Honda approval of the IPPAAR is designated by assignment of an IPPAAR Number

Note – the IPPAAR Tracking Number is NOT the same as the

IPPAAR Number

Note: Although Honda will support and sometimes complete the requirement section of the IPPAAR, the responsibility to properly verify any change point remains with the supplier.

Does this

IPPAAR affect

multipl No

Yes

Supplier contacts each plant with change details

and coordinates joint conference

call / meeting


HSQM-0041 Page 10/11 04/01/2019

IPPAAR Advance Planning

The supplier is responsible to create a quality confirmation plan and schedule to verify the change (may include testing, document revision, identifying time constraints, etc.). The schedule outlines all activities needed to implement the change. For example - when test parts will be available, when the dimensional confirmation will take place, when any outside testing will be performed and completed, etc. Important notes for IPPAAR Planning The supplier is responsible to contact the Honda window department, and

together set the target shipment/delivery date. Honda quality and purchasing work with the supplier to set dates (lead-time).

If the date will not be met, the supplier is responsible to contact Honda. The supplier is responsible to review the plan with Honda representatives

so Honda input can be integrated into the plan (this will reduce last minute additional requests).

The supplier is responsible to submit the completed IPPAAR, confirmation plan and schedule as soon as possible. The Initial Production Parts Quality Assurance Declaration must be attached to ensure the Companies OEM Company / Facility QA Representative or Equivalent has reviewed the changes and ensures that the changed parts meet all of the Quality Requirements.

If the IPPAAR process cannot be completed before parts are to be shipped (e.g. a welding robot breaks down and the process is done by hand) contact Quality immediately. Quality will provide instructions and requirements to suppliers in this situation.

Fulfilling IPPAAR Requirements

There are two items the supplier needs to keep in mind while working towards fulfilling the IPPAAR requirements The period of confirmation could range from a week to months depending

on the confirmation items While implementing the change, the supplier is required to maintain

stable production and consistent quality for current MP parts


HSQM-0041 Page 11/11 04/01/2019

IPPAAR Supporting Documents

The IPPAAR submittal may include any or all of the following Capability study (number determined by Honda) Sample parts (number determined by Honda) Material testing, if applicable Characteristic testing, if applicable Any documentation that needs updated Information from the supplier showing the changed part meets all quality

requirements and is fit for use, including a summary of confirmation activities and results

Other information as requested by Honda (e.g. layout or complete dimensional data)

The IPPAAR submittal must have an Initial Production Parts Quality Assurance Declaration attached prior to the IPPAAR being approved.

Honda Approval

When the supplier submits the IPPAAR and related materials for approval Honda reviews the IPPAAR documents to determine if other confirmation

items are needed, such as a QAV or additional testing. Honda evaluates the IPPAAR results and sample parts. Honda's decision

is entered into the system. Once all requirements have been met, and approval given, the supplier is

permitted to ship the initial production parts (MP).

Important Notes

Key Points If changed parts that require advance approval are shipped without that

approval, those parts may be rejected and/or counted against the supplier's index rating. Rejecting or indexing may occur whether or not an IPP tag was sent.

MP parts are not to be shipped until the supplier receives the approved IPPAAR or other formal part approval (e.g. QAN used at NM timing). If the supplier has not received approval and MP shipment delay is possible, the supplier is responsible to contact the Honda supplier representative immediately.

An approved IPPAAR has an IPPAAR Number.

IPPAAR Timing

The IPPAAR is sent with appropriate lead-time prior to delivery of the first lot. If PQ/PH requires a check or testing of the part, the supplier needs to submit the IPPAAR early enough to allow sufficient time for processing.

Honda Supply Parts Trouble Management ______________________________________________________________________________

HSQM-0083 1/1 07/01/15

Language Screen

Background DSPS (Domestic Supply Parts Supplier) and JSPS (Japan Supply Parts Supplier)

parts are purchased by Honda then delivered to a supplier to be used in their process. Honda has ultimate quality judgment for these parts.

Purpose/Scope DSPS/JSPS part problems identified at the Direct Supplier must be handled in a

systematic way. This procedure defines the responsibilities for

Direct Supplier (DS) or Tier 1 Honda Quality (HQ) Honda Purchasing (PH) Domestic Supply Parts Supplier (DSPS) or Tier 2 Japan Supply Parts Supplier (JSPS)

Responsibilities Honda

Quality responsible for DSPS and JSPS parts at the Direct Supplier Resolves discrepancies between the Direct Supplier and DSPS/JSPS

Direct Supplier

Responsible for NG part identification and initial containment. Initial containment is noted on the trouble report containment screen by indicating the “Inspected Quantity” and the “No Good Quantity”.

Write and submit a trouble report via NARS at time of occurrence Write and submit an initial trouble report via NARS for process inherent

defects by 25th of each month. Honda, the Direct Supplier, and the DSPS/JSPS must agree on “inherent defect” prior to submission of an inherent trouble report.

Tier 1 supplier can be indexed for out of standard parts, if they are responsible to contain per the PQCT and/or operation standard.

DSPS/JSPS Supplier

Responsible for inspection, manpower requirements, and part disposition Has final responsibility for scrap cost and rejected part replacement Will be indexed via HTR/ITR Respond as required with countermeasure activity.

Defect Report To communicate supply part problems to other Honda plants use the trouble report in

NARS located on the Honda Supply Team portal.

D.S.P.S. FLOW Honda Purchasing

(PH)DSPS Supplier (Tier 2)

Used For Process Inherent Defects

Used For Defects Requiring C/M and/or

Inspection

Direct Supplier (DS) Tier 1

Honda Quality (HQ)

* Receive Reply / Update HTR

* Submit rejection

* Add sort sticker on first good lot

* Countermeasure problem and reply

* Submit an Initial trouble report to HQ by 25th of each month* Receive Honda credit

* Receive DS monthly initial trouble report by 25th of each month* Complete part rejections and dispositions for NG parts

* Receive HTR* Issue Return Authorization (RA) # to DS for NG parts

* Consensus on inspection, manpower requirements, and part disposition

* Responsible for inspection, manpower requirements, and part disposition

* Record first good lot information into HTR

* Receive HTR* Receive Honda debit* Pay Honda

* Review problem* Re-order parts if necessary

* Complete part rejections and dispositions for NG parts* Update trouble report with rejection information

* Receive Honda credit for T2 rejected parts

* Close trouble report (this process could involve many approval steps)

* Receive Honda debit for containment and/or rejected parts* Pay Honda

* Initial containment of NG parts until DSPS can cover inspection* Make sure Op Stds are written and used correctly* Consensus on inspection, manpower requirements, and part disposition

* Accepts Initial trouble report* Confirm DSPS problem * Confirm necessary containment activity is taken* Set Limit Samples to judge parts if necessary* Make sure Op Stds are written

* Responsible for NG part detection* Notify HQ of concern* Submit an initial trouble report to HQ via NARS* Initial trouble report to include suspect rejections and pertinent investigation data

* Confirm with HQ and DS that Op Stds are written and used correctly

* Review problem* Re-order parts if necessary

* Receive parts from Tier 2.* Parts shipped to Honda purchase order

HSQM-0084 1/1 07/01/15

J.S.P.S. FLOW Honda Purchasing

(PH)Honda Motor (IOO's)

Used For Defects Requiring C/M and/or Inspection

Used For Process Inherent Defects

Direct Supplier (DS) Tier 1

Honda Quality (HQ)

* Responsible for NG part detection* Notify HQ of concern* Submit Iinitial trouble report to HQ* Initial trouble report to include suspect rejections and pertinent investigation data

* Responsible for NG part containment (own manpower or sort company)* Make sure Op Stds are written and used* Consensus on part disposition

* Complete part rejections and dispositions for NG parts* Update trouble report with rejection information.

* Receive Reply / Update ITR

* Submit rejection results

* Add sort sticker on first good lot

* Countermeasure Problem and Reply

* Submit monthly initial trouble report to HQ by 25th of each month* Receive Honda credit

* Receive International Trouble Report (ITR) * Notified of NG condition and inspection activity.

* Record first good lot information into ITR

* Receive Honda debit* Pay Honda

* Receive initial trouble report* Confirm JSPS problem * Confirm necessary containment activity is taken* Set Limit Samples to judge parts if necessary* Make sure Op Stds are written* Summarize ITR, Japan Label info. Sent to MS to create GTR

* Review problem * Re-order parts if necessary

* Honda authorizes DS to use own manpower or sort company* Consensus on part disposition and manpower

* Receive initial trouble report by 25th of each month* Complete part rejections and dispositions for NG parts

* Review problem * Re-order parts if necessary

* Receive Honda credit for T2 rejected parts

* Close trouble report (this process could involve many approval steps)

* Receive Honda debit for containment and/or rejected parts* Pay Honda

HSQM-0085 1/1 07/01/15

Non-conforming Product

HSQM-0038 Page 1/6 05/01/11

Background Non-conforming parts (also referred to as rejects) are parts failing to conform to

quality requirements. Honda judges the non-conformity to be the supplier's responsibility if any of the following conditions exist

• The part does not conform to the current drawing or specification • The part does not conform to applicable quality standards • The part does not conform to limit or master sample guidelines • The part does not perform or function per design intent • The part does not conform to expected commercial quality


HSQM-0038 Page 2/6 05/01/11

Requirements When Honda informs the supplier that non-conforming parts have been found, the

supplier is required to

1. Undertake inspection, segregation, and/or repair of suspect parts.

2. Analyze the cause(s) of the non-conformance and implement appropriate corrective action.

3. Report results of sorts, suspect lot range information, repairs, investigations and

corrective actions to Honda.

4. Confirm effectiveness of corrective actions taken through necessary testing, part analysis, dimensional layout, process data collection, “bully” testing, etc.

5. Reflect results to similar systems or processes and to the supplier's problem

history records.

Note – The supplier must immediately notify the Honda Quality Representative at the affected production facility and follow the non-conformance requirements when:

1. The supplier determines that a non-conforming product has been supplied from

the supplier’s facility to a Honda production facility.

2. The supplier has been notified by the National Highway Traffic Safety Administration (NHTSA), other governmental authority, or another motor vehicle manufacturer that the product they have supplied to a Honda production facility or to another vehicle manufacturer that is identical to or substantially similar to the product that was supplied to a Honda production facility, could reasonably impact motor vehicle safety or result in non-conformance with Federal Motor Vehicle Safety Standards (FMVSS).

3. The supplier commences an investigation relating to product that has been

supplied to a Honda production facility concerning potential defects that could reasonably impact motor vehicle safety or result in non-conformance with FMVSS.

4. The supplier notifies NHTSA of or reports to NHTSA about a death claim and/or

notice it has received relating to product that has been supplied to a Honda production facility. Notice to the Honda Quality Representative under this paragraph shall, at the latest, be concurrent with the submission or quarterly reports or other notification to NHTSA.

The supplier’s notification to the Honda Quality Representative under items 2, 3 and 4 above must be confirmed in writing. Upon notification from the supplier as set forth in items 1-4 above, the responsible Honda associate shall immediately respond in a manner consistent with Honda’s non-conformance procedural requirements.


HSQM-0038 Page 3/6 05/01/11

Undertake Inspection, Segregation and/or Repair

The following list clarifies the requirement to undertake inspection, segregation, and/or repair of suspect parts.

• Inspection, segregation, and/or repair may be required at a supplier, at a warehouse or consolidation center, or at a Honda facility. Honda has the right to charge for any cost incurred - including administrative costs for inspection, segregation and/or repair at a CC or Honda facility.

• Any required inspection, segregation, and/or repair will be undertaken without delay,

upon direction from Honda. • If temporary workers are used to inspect, segregate and/or repair suspect parts, those

workers are contracted by the supplier from a temporary service and are supervised by the supplier.

• The supplier is responsible to provide the necessary tools and supplies for

repair/rework/sort. • All supplier associates or contracted temporary workers at Honda facilities must wear

safety shoes and safety glasses, as necessary, for the supplier associates. If additional safety equipment (e.g. bump caps or sleeve covers) is provided by Honda, the supplier is responsible for those items.

• The supplier is responsible for all labor and material costs of inspection, segregation,

and/or repair incurred by Honda for the repair of completed vehicles or engines due to the supplier’s non-conforming parts. This includes time spent containing and/or repairing parts/units.

• The supplier is responsible for the costs of any expendable items (e.g. gloves, sandpaper,

sealer, etc.) used in the inspection, segregation, and/or repair. • The supplier is responsible for the cost of any complete or partially complete vehicle or

engine that cannot be offered for retail sale due to the supplier’s non-conforming part. • At Honda’s discretion, suspect lot(s) of parts may be returned to the supplier for

inspection, segregation, and/or repair. In this case, the entire lot(s) may be charged as rejects for financial and inventory reconciliation.

• Honda reserves the right to disposition nonconforming parts (repair, scrap or return to

supplier). The supplier is responsible for all cost of returning nonconforming product. • Honda reserves the right to disposition parts as reject/repaired if the decision is made to

repair nonconforming product (or handwork the mating parts). If a decision is made to handwork all parts due to difficulty in sorting out the percentage of nonconforming product, Honda reserves the right to determine the percentage to disposition as reject/repaired in order to accurately reflect the delivered quality.

• The supplier submits an operation standard for Honda confirmation prior to actual

repair/rework/sort activity. Supplier/sort associates must have knowledge of the repair/rework/sort requirements.

• Supplier associates must conform to Honda’s ISO 14000 procedure; specifically

concerning chemical usage.


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Loss of Containment Requirements

When the Supplier identifies they have lost containment of a quality issue • On discovery that the containment of non-conforming product has been lost,

the Supplier must immediately notify each Honda plant’s Parts Quality Department.

• Time is the most essential element to prevent the defects from reaching our customers. The Supplier shall give Honda the basic nonconformance description and their proposed method for inspection.

Note: If the Parts Quality Department cannot be contacted, notify the Parts Procurement Department.

Analyze the Cause, Implement Corrective Action

The following list clarifies the requirement to analyze the cause(s) of the non- conformance and implement appropriate corrective action. • The supplier is responsible to identify the root cause(s) of the non-conformance

and implement effective corrective actions to the processes and management systems to prevent recurrence.

• Corrective actions are applied to similar systems or processes. • The supplier is responsible for testing and related costs to confirm the root cause

of the non-conformance. • The supplier is responsible to confirm the effectiveness of corrective actions

taken through necessary testing, part analysis, dimensional layout, process data collection, “bully” testing, etc. and any related costs.

• The corrective action requires use of the IPP system, including the IPPAAR. • The corrective action requires revision of quality documents if the change has an

effect to the documents (e.g. PFMEA, PQCT and process operation standards).


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Report Results to Honda

The following list clarifies the requirement to report results of sorts, suspect lot range information, repairs, investigations and corrective actions to Honda. • At Honda discretion, results of sorts, repairs, and investigations are reported

using the North America Reporting System (NARS). • Corrective actions are reported using NARS via a Trouble Report Reply (TR

Reply) or 5 Principles for Problem Solving (5P) form. • In addition, steps taken to confirm corrective actions effectiveness and the

results of those confirmation steps are also reported using NARS via 5 Principles for Problem Solving (5P) form when required by Honda.

• Honda considers the scope and severity of the problem when setting the extent of

reporting results. Preliminary results may be required at Honda’s discretion.

Reflect Results The supplier is responsible to apply preventive actions to similar systems or processes (parallel analysis) and update past problem history lists or “lessons learned” to reflect into future process planning.

Additional Clarifications

The following list clarifies additional requirements. • Failure to properly adhere to the IPP system may result in index points. • The affected plant’s PQ/PH departments have final responsibility to judge part

quality conformance and responsibility for any non-conformance. The appropriate PQ/PH department reviews any rejections disputed by the supplier.

• The supplier has one month from the time a report is closed to dispute the report.

Supplier Initial Response

The supplier’s initial response is required at the time of notification from Honda. The initial response includes • Method of containment • Action plan • Any investigation or analysis results available • Others items as requested by Honda


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Supplier Final Response

The reply due date and method are noted on the Trouble Report. The supplier’s final response includes: • Appropriate management approval (prior to returning to Honda) • When attachments are used indicate on the reply form (e.g. “attachments 4

pages”) and attach in a logical sequence. • If corrective actions cannot be fully implemented by the response date, a

schedule of correction activity must be submitted. • If the due date for the response cannot be met, the supplier must contact the

Honda PQ/PH representative prior to the due date using the Extension Request in the NARS system. A new due date may be arranged provided the supplier is making a good faith effort to resolve the problem.

Charge Backs Honda charges the supplier for expenses due to non-conforming product. Examples

of items charged for include (but not limited to)

• Downtime • Honda materials the supplier uses to sort or repair parts • Honda’s expenses for containing, sorting, repairing • Consolidation Center or in-house at Honda fees (e.g. access to parts or pallet

moves) • Shipping fees for replacement parts (including export customers) • Investigation costs (e.g. QAV, layouts, testing, etc.)

IPP Related HTRs

The IPP procedure states "If changed parts which require advance approval are shipped without that approval, those parts may be rejected and/or counted against the supplier's index rating. Rejecting or indexing may occur whether or not an IPP tag was sent." Non-approved parts sent in without an IPPAAR receive an HTR.

5 Principles For Problem Solving

HSQM-0039 Page 1/8 07/01/15

How Honda Uses a 5P

The 5P is an additional method to respond to a trouble report. It gives additional information and greater detail than a trouble report reply. A 5P is required for all problems with an importance rank of "A". Honda may also request a 5P for other problems based on potential impact to the customer, recurrence or Honda downtime.

Definition of a Problem

A problem is a deviation between what should be happening and what is actually happening.

The 5 Principles

The 5 Principles for Problem Solving are Definition of the problem Identification of the root cause Implementation of corrective countermeasures Confirmation that the countermeasures implemented are effective Feedback/feed forward of problem information

Primary Purpose of 5P at Honda

The primary purposes of the 5P at Honda To permanently resolve recurring and high impact problems To standardize the problem solving process To effectively and efficiently communicate problem solving activities to other

associates (Honda or supplier) To create a working history of a problem and the countermeasures that were taken to

correct the problem for future reference

The 5P Sheet Items to note concerning the 5P sheet

The 5P sheet must be signed in ink when being formally provided to

Honda or contain typed names when submitted via the Honda Portal Staple/attach additional support pages to the 5P when necessary Honda reserves the right to reject any submitted 5P that lacks adequate

information


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Problem Statement (Box 1)

The first step to solving a problem is to learn what happened. Review the failure information available Examine the failed object and understand the problem Go to the spot and see the actual situation Ask the associates involved about the problem The problem statement is a clear specific statement of the problem. It includes two things The object - the specific part, object or thing with which you are having a

problem The defect - what is wrong with the object

Discovery Information (1A)

This section provides specific information about the problem. Answer the 14 questions in detail in the following categories Who What Where When Why How How many Make sure you drill down to very specific information using the 5Ws 2Hs. If necessary, contact your Honda rep to clarify or acquire additional information about the failure.


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Problem Details (1B)

This section includes analysis details about the problem that supports the discovery information section 1A. When analyzing parts

Details can be obtained via Visual observation Dimensional comparison Test results Technical reports Tear down analysis Part markings, lot codes, QA marks, etc.

When analyzing processes Process flow diagrams Statistical history

Trends Capability index (Cpk) Control charts Percent no good Reject history

Document any changes that may have taken place on or around the first known problem date or time.

Consider these areas Machine Material Man Method Other


HSQM-0039 Page 4/8 07/01/15

Identify Possible Causes (2A)

In this section begin to identify possible root causes for the problem. Brainstorm for causes (consider information from 1A and 1B) Use 5Ms for hard side issues and the 4Ps for people or performance issues

Man (People) Method (Procedures) Material (Plant) Machine (Policy) Mother Nature

In the clarification column eliminate any causes that can be quickly eliminated

using data.

Expand on Possible Causes (2B)

In this section use cause and effect diagrams to perform a cause analysis. Three cause and effects diagrams that can be used are – 1) Fishbone, 2) Org Chart, and 3) Mind Map. The cause analysis enables documentation of the problem causes. In this section the single level causes from section 2A are extended into multi-level causes by using the Why, Why analysis. Benefits of cause analysis Levels of cause can be identified and communicated clearly Relationships among causes can be easily seen Multiple contributing causes can be identified Provides more countermeasure targets Focus on the causes of the problem, not symptoms of the problem Build support for the problem solutions by gaining consensus of the problem

solving team

Test to Determine the Most Probable Cause

After identifying possible causes, test them against the facts in sections 1A and 1B. Eliminate any possible causes that don’t make sense From the probable causes that you have not eliminated choose the Most

Probable Cause from the data in 1A and 1B Go to the spot and prove that the Most Probable Cause is the True Cause


HSQM-0039 Page 5/8 07/01/15

Non-detection Non-detection refers to a situation where the problem was not detected before moving on to the next customer. To solve a non-detection problem, ask Detection Where was the problem first discovered and who discovered it (market, in-

house, etc.) How was the problem found Does the problem exist on similar products Does the problem exist on different shifts, lines, etc. Non-detection Was the problem discovered as early as possible Why wasn't the problem detected before now

Identify Root Cause (2C)

This section shows the relationships among causes from the two Most Probable Causes. Transfer the cause from page two, Box 2B, to this section (add additional

columns/rows as necessary) Mark each root cause that can be countermeasured

Root Cause Selection Justification (2D)

This section identifies which root causes will be countermeasured and why those causes were chosen over others. Identify which causes will be countermeasured Indicate why these causes were chosen Clarify causes with illustrations and explain how verification was done

Counter-measure (Box 3)

This section initially identifies what was done to temporarily countermeasure the problem and its effects. Additional permanent countermeasures that are planned or completed must also be documented.


HSQM-0039 Page 6/8 07/01/15

Implementing Counter-measures

Below are some guidelines for implementing countermeasures. Understand work flow in the area Look at each level of the cause Consider quality control goals Test countermeasures Establish improvement goals and measures Carefully plan implementation, communicate and prepare the plan Could the countermeasure create another problem in the process or for

other associates Implement countermeasures Replace temporary countermeasures with permanent ones as soon as

possible Caution The focus of countermeasure activity often becomes the man rather than

the system. The root cause is often not associate error, but rather a system breakdown such as

Unconfirmed process changes Tools or information not being available Poor training or poorly designed processes or equipment

Focus on the information gathered and analyzed in the 5P process to avoid this error


HSQM-0039 Page 7/8 07/01/15

Temporary and Permanent Counter-measures

Items to include when documenting temporary and permanent countermeasures Temporary Identify what was done to stop the error from continuing and/or to keep

production flowing Identify how parts/units sent downstream will be fixed and who is doing

the repairs (how will this be tracked) Identify what potential problems exist while operating under abnormal

conditions, how potential problems will be prevented and what will be done if the potential problem happens (contingency plan)

Record information that identifies when the abnormal production occurred (date, time, lot numbers, VINs, IPP Tag number of first C/M shipment, etc.)

Permanent What permanent countermeasures are being taken How will the countermeasures be tested to confirm desirable effects What effects are predicted When, where and how will the countermeasures be implemented Who was involved in the countermeasure process What operation standards had to be modified and by whom Use illustrations to help clarify understanding Attach any additional documentation to the back of the 5P

Counter-measure Effectiveness (Box 4)

In this section record the activities, methods, and results of the countermeasures that were implemented and what was done to ensure they are effective and remain in place. Who confirmed the countermeasures are effective How and when were the result of the countermeasure checked Did the countermeasure achieve 100% results If applicable, record the pre, actual and post PFMEA countermeasures

results, where 'pre' is the number that was on the PFMEA when the issue occurred, the 'actual' is what the actual number was at the time of the incident, and 'post' is the number after corrections were put in place

What tests have been used to verify countermeasure effectiveness Record results after the countermeasures are implemented


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Feedback / Feed Forward (Box 5)

In this section document communication about the problem to other areas that require or could benefit from the information. Information about countermeasure activity is shared

Horizontally With areas having similar problems throughout the organization Vertically through the organization With the area/individuals where the original problem was reported With Process Engineering

Update all related documents

FMEA PQCT Op Standard Other

Record the following information Names of associates/departments who received feedback / feed

forward Method used to feedback / feed forward Who performed the feedback / feed forward Dates of feedback / feed forward

What to do Next

Present 5P to the department that found/reported the problem, get 5P approval

Share the 5P with others who need the information it contains Keep a copy on file in case a similar problem occurs Have information available for further analysis

Challenge Quality Process Overview

Purpose The purpose of this document is to provide an overview of Honda North America Challenge Quality (CQ) program.

Scope This document applies to all market claim parts returned through the Challenge Quality program.

CQ Process Overview

The chart below shows the CQ process overview.

HSQM-0089 Page 1/1 11/01/2011

Index System

Printed From a Controlled Source, Title: 4-5 Index System, Issued: 7/19/2019 Ref: HSQM-0008 Rev: 0, Printed: 7/24/2019

Page 1 of 6

Background The Index system is used to assess effectiveness of suppliers Quality Management System and problem severity of part problems and, by summation the potential impact of suppliers on Honda and Honda’s customers.

Scope This applies to OEM (Original Equipment Manufacturer) purchased

part/material problems. All non-conforming part problems receive an index rating.

Rating Process

I. Each problem is assigned a severity rank based on the impact or potential impact of a problem on the unit. II. Each problem is assigned index points in order to evaluate the impact of the suppliers on Honda. Index is determined by two categories.

1. Severity Rank – Assigns a rank to determine the index value of a problem based on the failure or potential failure mode as defined in the Severity Table.

2. Number of Problems Rank – Assigns a rank based on the quantity of

Non-Conforming products for an individual Trouble Report.

Mass Production - Denotes number of non-conforming products received by Honda.

Warranty - Denotes number of warranty claims.

Severity Rank + Number of Problems Rank = Total Index

Parts quality problems at the plant are assigned Quality index points in order to evaluate the impact or potential impact of suppliers on Honda’s manufacturing operations. Note – Quality index points are summed for each month, then, reported within the Supplier Performance Reporting System. Warranty problems are assigned warranty index points in order to evaluate the impact of suppliers on Honda’s customers. Note – warranty index points are summed for each month, then, doubled within the Supplier Performance Reporting System to indicate the impact to both Honda and the vehicle owner.

Index System


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Severity

Rank

Index Points

Definition

A 100

1. Conditions that may impair Driving, Turning, Stopping

2. Conditions that may result in customer shock, burn or injury

3. Condition that may cause fire. 4. Condition that may cause

Environmental pollution. 5. Condition that may impair

passenger protection 6. Conditions that do not comply to

regulatory requirements.

B 20 Other than “A Rank” Functional Issues C 4 Other than “A Rank” or “B Rank”

Assigning Number of Problems Rank

The table below explains how number of problems rank is assigned to a HTR or MIR, and the corresponding index for said Rank.

Number

of problems (index)

Quantity of problems A,B,C,D ranking A rank Index: 70 B rank Index: 50 C rank Index:10 D rank Index: 2 100 pcs or more 99~10 pcs 9~2 pcs 1 pcs

The number of non-conforming products that are received. This would include parts returned, reworked/repaired or scrapped.

Rank Determination

The table below defines how each problem is assigned a severity rank and index.

Index System


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Notes A mis-labeled part that is installed and causes a quality problem generates a HTR and obtains a

Ranking. This does not apply to conforming parts in a mis-labeled container. That is considered a mis-shipment and is handled through Parts Procurement.

Non-conforming DSPS Parts

DSPS (Domestic Supply Parts Supplier) parts are purchased by Honda then sold or delivered to a supplier to be used in their process. Non-conforming DSPS parts may be indexed according to the following:

Parts confined to the Tier One Supplier – evaluate according to the “Assigning Rank" section.

Parts reaching Honda Problem is ranked and index assessed Both the supplier that causes the defect and the subsequent supplier can

be charged with an HTR, if the subsequent supplier is required to confirm quality of the defect that occurs (should be indicated on PQCT)

DSPS HTRs The Tier 1 supplier receives non-conforming parts from the Tier 2 that is

a DSPS part The Tier 1 supplier enters an Initial (INI) report in the North America

Reporting system (NARS) and submits the report to Honda. The report should include the Tier 2 supplier, part number, investigation data, and images of the part concern.

Honda approves or rejects the INI report On Honda approval, the report is changed to the appropriate NARS

trouble report type and follows the flow of that report type On Honda rejection, the report is returned to the Tier 1, denying the

report or requesting additional information

IPP, ASN and Suspect Parts HTRs

When a supplier fails to conform to the IPP system a C-rank HTR may be issued. When the manufacturing lot number is missing from the ASN (Advance Ship Notice); a HTR may be issued. The rank and index will be determined according to the seriousness of the loss of traceability. Any part arriving with an indication of being a suspect part (e.g. has a hold tag, red label, etc.) may receive a C-rank HTR. See the Identification Control procedure for more information.

Index System


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Additional Clarification

A new HTR / MIR is generated when non-conforming parts are received again: after a temporary inspection or repair after a countermeasure has been implemented after the countermeasure due date to Honda Note - A new report may be generated monthly for on-going problems (containment not possible or not 100% effective).

Chargebacks See HSQM-0038 Non-Conforming Product procedure for details related to

supplier chargebacks.

How Honda Uses Index Data

The Index data is used to assign supplier class rankings. See HSQM-0010 Supplier Quality Performance Rating for further explanation. Trouble report information is also used when reviewing process improvements for New Models.

Similar Part Numbers

Defects that are produced by one machine or process may be considered as one problem regardless of the different part numbers affected. If similar but different machines or processes generate similar defects at Honda, each machine or process may be considered an individual problem.

For Your Information Reports

For Your Information (FYI) reports may be entered into NARS when Honda cannot determine if the cause is Supplier related. FYIs are not included in the supplier’s index.

Honda Trouble Reports

Honda Trouble Reports (HTR) may be entered into the North America Reporting System (NARS). HTRs are written for parts found non-conforming during mass production. HTRs are included in the supplier’s index. The report is entered as a Honda Trouble Report (HTR) and is closed upon approval of the corrective action. HTRs with a required feedback of “Accumulate and Feedback upon Request” do not require a response to Honda unless otherwise noted.

Index System


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Initial Reports Initial Reports (INI) are reports that are entered into NARS by a Supplier. Upon Honda approval of the INI report, the report may be changed to a HTR and included in the DSPS supplier’s index. Initial Reports: CQ (Challenge Quality) Supplier’s will be required to issue a INI report in NARS for supplier manufacturing issue’s found through the CQ analysis process, once the supplier has completed the analysis and investigation on the returned CQ part . Upon Honda approval of the INI report, the report will be changed to a MIR (Market Impact Report) and included in the Supplier’s Index.

International Trouble Reports

International Trouble Reports (ITR) may be used for the following reasons: When a problem is reported from another Honda plant (e.g. Brazil or

Mexico) When the problem is caused by a Japan supplier Note – any mention of HTR in this document includes ITRs

Market Impact Reports

All supplier responsible warranty problems will be entered into NARS and will be included in the supplier’s warranty index. The report is entered as a Market Impact Report (MIR) and is closed when the warranty issue is closed.

Not a Parts Problem Reports

Not a Parts Problem Reports (NPP) may be used when PQ/PH investigates an issue and it is determined it is not a supplier’s responsibility. Suppliers cannot view NPP reports.

New Model Quality Reports

Parts found non-conforming during New Model trial events are entered into the NARS system, but are not included in the supplier’s index. The report is entered as a New Model Report (NQR) and is closed when the problem is counter measured. Note: Problems for carryover parts are indexed using an HTR. Problems on sellable units are indexed using an HTR.

Index System


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Request for Information Reports - RFI

Request for Information Reports (RFI) are used when a problem is under investigation and responsibility is not yet known. They are used to request information or data from a supplier to determine root cause and responsibility. Suppliers must respond in a timely fashion to ensure problems are addressed quickly to protect Honda and its customers.

Environmental ETR’s are used when an environmental issue has been reported. Trouble Report - ETR

Controlled Containment

HSQM-0061 Page 1/5 04/01/16

Purpose This procedure describes the activity required, by the supplier and Honda, when a process or supplier’s containment system is deemed out-of-control and requires a secondary inspection/controlled containment process to be performed prior to shipping product.

Scope This procedure applies to all OEM (Original Equipment Manufacturer)

Honda purchased parts.

Responsibility Honda informs the supplier of parts that require a secondary inspection

process to sort for nonconforming product. The supplier must adhere to the policy outlined in this procedure.

General Controlled containment requires a supplier to put in place a secondary

inspection process. This inspection is the result of a process or containment system that continues to produce and/or ship non-conforming product. It is to be carried out at the supplier’s manufacturing location (or a location to be agreed upon between Honda and the supplier) and is in addition to the normal process controls. The data collected from this secondary inspection process is used to determine if the countermeasures implemented at the process or system improvements are effective, and when a supplier may return to the previous level or eliminate the controlled containment process.

Definitions of Controlled Containment Levels

There are four levels of controlled containment Level I - allows the supplier management to implement hard

countermeasures at the process to eliminate the defects from occurring or systemic improvements to prevent non-conforming parts from being shipped. Generally, this level is skipped and the process starts at Level II containment.

Level II - is a secondary inspection process implemented by the supplier but

isolated from the normal process flow. This inspection is to be performed by the supplier’s permanent manpower.

Level III - is the same as Level II, but performed by an impartial 3rd party

inspection company (as agreed upon by Honda and the supplier) and paid for by the supplier.

Level IV - may be required in special cases as directed by Honda. This

containment must be performed outside the supplier’s facility at a 3rd party inspection company or at a location determined by Honda.


HSQM-0061 Page 2/5 04/01/16

Key Components

Key components for implementing controlled containment

Honda determines that the current process controls or containment systems at the supplier are not adequate to prevent Honda from receiving non-conforming product

Honda can determine the containment level or require a supplier to skip a level based on the potential exposure of non-conforming

Honda communicates, to the supplier’s management; the need to implement controlled containment activity - including each company’s role and responsibility. Honda also communicates the criteria for the escalation/step down of containment level

Honda and supplier management reviews non-conforming issues internal and external of the controlled containment area to determine either escalation or step down of containment level.

IPPAAR/IPP system must be used when it applies.

Determination of Parts Requiring Controlled Containment

The Honda facility experiencing the non-conformance makes the final determination whether a part is added to the controlled containment list; based on the supplier’s ability to effectively implement countermeasures at the process. The criteria for implementing controlled containment may include, but are not limited to Repeat occurrences Units needing repair (on-line or off-line repairs) Downtime Duration of the problem Index points (rank and nuisance) associated with the problem Number of rejections Warranty Inadequate containment or countermeasures of non-conformances


HSQM-0061 Page 3/5 04/01/16

Level I Containment

The supplier is required to Direct root cause analysis using the 5P format. Implement all countermeasures (hard and soft side) as determined by root

cause analysis. This includes process/fixture modifications, quality documentation updates and training of all required associates.

Develop any master or limit samples approved by Honda, as required. Implement an “ok to ship” procedure to assure parts were produced after

hard countermeasures were implemented at the process. This helps to determine effectiveness.

Implement data tracking of all rejections at the process to determine effectiveness of the countermeasures (fax to Honda daily or during the production run).

Implement quick feedback to the process.

Honda actions Notify the supplier that a part, or supplier’s containment system, is being

considered for the controlled containment process. Honda may perform a Level I Containment QAV to review 5P and

countermeasure activity taken by the supplier. Honda may perform a monthly review(s) at the supplier to confirm

results. If defective parts escape the supplier, Honda may request Level II

containment.


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Level II Containment

The supplier is required to Develop an in-house containment area isolated from the current

production flow. The containment area should be distinct to the plant with proper

equipment and lighting. The supplier must develop a material flow including part

identification to assure incoming and outgoing part flow. The associates manning the inspection area must sign-off training

documents, including operation standards. Quality standards, limit samples and other needed information

must be available to the containment associate. Rejection data from the sort activity is required and posted in the

area and reviewed by management daily. Countermeasure activity taken based on the inspection findings

must be clearly documented.

Supplier must provide experienced manpower with necessary back-up manpower to assure consistency.

Supplier must send data to Honda daily (or during each production run) in order to review the effectiveness of the countermeasures at the process.

Honda actions Same as Level I except Honda may perform a Level II Containment QAV

and hold monthly management meetings to review containment area effectiveness and activity to drive countermeasures back to the process.

Level III Containment

The supplier is required to Same as Level II containment except the supplier shall hire an impartial

3rd party inspection company to inspect at the supplier’s facility. This company shall be agreed upon between Honda and the supplier. The supplier will be responsible for managing and paying this company.

Honda actions Same as Level II.


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Level IV Containment

This level of containment is implemented only in special cases in order to protect Honda from non-conforming product or failure of the previous containment levels. The supplier is required to Establish, with agreement from Honda, an off-site inspection facility to

contain non-conforming product. This inspection area could be an off-site warehouse or independent inspection company. The supplier is responsible for managing the sort activity and meeting all of Honda’s shipping requirements.

All other requirements will be the same as Level II. Honda actions Same as Level II.

Timing The supplier has two working days once notified (unless otherwise negotiated

between Honda and the supplier) to implement controlled containment procedure/escalation.

Escalation/Step Down Criteria

The escalation and step down flow is determined as follows unless otherwise determined by Honda. Escalation Flow The supplier may be required to go to the next level of controlled

containment if there is a failure in the system that allows non-conforming product to be shipped to Honda.

Level IV containment is used only in special cases as determined by Honda.

Step Down Flow A supplier is allowed to step down to the previous level of containment

based on the effectiveness of the countermeasure(s) implemented at the process and with mutual agreement with Honda.

Sort Label

HSQM-0067 Page 1/3 07/01/15

Background Through the normal practice of manufacturing processes, issues arise that require

temporary containment at suppliers. Honda requires notification and identification of these "sorted parts." Honda requires a label to identify these parts. Honda also requires notification of sorted parts via the ASN (Advance Shipping Notice). Note – suppliers are still required to send IPP Tags for other part/process changes.

Scope

This procedure applies to all suppliers that supply OEM parts and materials to Honda North American plants.

Requirements

When Honda informs the supplier that non-conforming parts have been found, or the supplier finds non-conforming parts in-house that may not have been contained, the supplier is required to Sort all in-house stock and label the first container of inspected parts. Follow label attachment requirements detailed below. Send notification through the ASN to Honda.

Enter the HTR number in the IPP Tag Number field (for sorts only – all other IPP tags require the actual IPP number in this field).

Ensure the entire HTR number, including the beginning letters, is used (e.g. for HTR number VQMP123456, “VQMP123456” must be entered in the IPP number field).

Enter reason code 11 in the IPP Reason Code field. The Advanced Ship Notice number should be entered into the HTR Reply

section. Note - A Sorted label implies that all product within a shipment has been confirmed.

Sort Label

HSQM-0067 Page 2/3 07/01/15

Label Attachment

Follow these guidelines when attaching labels to containers. Wrap two labels around opposite corners so they can be seen from all sides Do not cover any other labels (e.g. part number or bar codes)

DSPS/JSPS

For DSPS /JSPS sorted parts Labeling The Tier 1 supplier transfers the DSPS supplier’s sort information onto a new

Sorted Parts label. The DSPS supplier's name and HTR number are transferred, but the Tier 1

supplier enters the part number that is on the ASN to Honda. If the Tier 1 supplier does not have the HTR number, the supplier contacts the

Tier 2 (DSPS) supplier or the Honda quality representative for the number. The supplier then follows the label attachment guidelines above. Sorted parts received from suppliers outside North America might have an IPP

Tag to indicate sorted parts. The information on the tag is transferred to a Sorted Parts label and this procedure followed. Contact Honda if the HTR number is not on the IPP Tag.

ASN The Tier 1 supplier enters the DSPS supplier’s HTR numbering the IPP Tag

number field.

DSPS Tier 1

Sort Label

HSQM-0067 Page 3/3 07/01/15

Enforcement and Supplier Accountability

Suppliers must take the necessary steps to train all appropriate associates and adjust related procedures. The Index System procedure in this manual explains the possibility of receiving a HTR if the supplier does not conform to the IPP system (change point control) or use the ASN correctly to relay sort information to Honda.

Identification Control

HSQM-0048 Page 1/2 07/10/06

Background At several Honda plants, Quality uses identification codes to signify various

part types. Suppliers are requested not to ship parts, to those plants, using the same identification markers. If parts are shipped to those plants with the noted identification marks, the parts may be rejected and/or an HTR written.

Identification Method

Honda uses tape, tags, dots, and paint as identification markers.


The table below lists the identification markers and the type of parts they signify.

Identification

Color

Effected Plants Signifies Red

AEP HPPG HTM IDPS MMP

Scrap parts or NG parts

Orange

AEP HPPG HTM MMP

On-hold parts (e.g. suspect non-conforming parts, IPPAAR parts waiting for inspection)

Purple

AEP HPPG HTM MMP

NM parts

Chartreuse HSC NM parts

Green HTM MMP

Masters for equipment


HSQM-0048 Page 2/2 07/10/06

Requirements • The internal color code system throughout Honda dictates that scrap parts,

on-hold parts and new model parts are color coded per the identification color chart above. Therefore, Honda (those plants listed above) cannot accept parts supplied with these color markings.

• Color codes as indicated on Honda drawings are an exception to this

procedure and should be noted during new model development and handled accordingly.

• Parts that are received at Honda (plants listed) with the above mentioned

color identification on them will be put on-hold. The supplier will be contacted to verify the reason for the color markings, and may be requested to repair the parts (remove the color ID) before being used.

• If parts are received at Honda (plants listed) with any form of

identification recognized by Honda as indicating scrap, on-hold or new model parts - they will be treated as a ranked quality problem. Index will be affected, an inspection may be requested, and a countermeasure will be required.

Minimum Test Requirements

Purpose The purpose of this document is to clarify and communicate minimum testing requirements to reduce no trouble found (NTF) conclusions during problem investigation.

Scope This procedure applies to all OEM purchased parts and material products shipped to North American Honda plants. This also includes any component parts shipped to a Tier 1 supplier. Primary application is on Market return parts but may be applied during investigation of factory return parts when requested by Honda.

This procedure applies to the following part families:

Electronic Assemblies (printed circuit boards) Electro – Mechanical Assemblies (i.e. Mirrors, switches, pumps etc.) SRS control units Dampers

Minimum Test Requirements Definition

The Minimum Test Requirements define the minimum testing Honda requires in applicable failure analysis. These requirements were established to identify quality defects that may go undetected during less comprehensive testing. These requirements are minimum test requirements. Honda may require additional analysis and test requirements where applicable.

HSQM-0108 Page 1/1 06/01/10

Electro-Mechanical and Mechanical Assemblies Minimum Test Requirements

HSQM-0111 Page 1/1 06/01/10

Electro-Mechanical and Mechanical Assemblies Minimum Test Requirements

The table below contains the minimum requirements for handling / analysis / testing of electro-mechanical and mechanical assemblies.

1) Test items with "Want" designation may be negotiated and required by individual Honda plant and supplier. 2) Proper ESD protection must be used during analysis to prevent damage to sensitive electronic components. 3) A, B, or C rank is determined by the failure mode of the part, not the rank of the part. Failure description:

A Rank Failure – failure results in a problem that leads to sudden loss of function; such as cannot turn, stop, go or loss of safety features. B Rank Failure – failure results in product performance impairment, not related to safety or government regulations. C Rank Failure – failure creates an appearance of non-functional dimensional variance.

Item Requirement A Rank Failure B Rank Failure

C Rank Failure

Visual Inspection Inspect for signs of damage, tampering, disassembly, etc.

Must Must Must

End of Line Function Test

Function test on manufacturing process test equipment or equivalent bench test equipment

Must Must Must

Humidity Test Function test after minimum 2hr soak at 95% RH

Must Want Want

High Temp Test Function test after minimum 2hr soak at 80˚ C

Must Must Want

Low Temp Test Function test after minimum 2hr soak at -40˚ C

Must Must Want

Operating Durability

Function test after minimum 5 cycles of 2hr soak at -30˚ C, 2hr ramp to 80˚ C, 2hr soak at 80˚ C

Want Want Want

Vibration Test No abnormal noise, function or loss of proper function

Want Want Want

X-Ray Perform X-Ray on returned part/component(s)

Want Want Want

Vehicle Test Perform on-vehicle test To be negotiated

with plant

To be negotiated with

plant

To be negotiated with

plant

Teardown Analysis Perform component level tear-down analysis of return

Want Want Want

Market Quality Warranty Data

Request market data Must Must Must

SRS Electronic Control Unit Assemblies Minimum Test Requirements

SRS Electronic Control Unit Assemblies Minimum Test Requirements

The table below contains the minimum requirements for handling / analysis / testing of SRS Electronic Control Unit assemblies.

Note: Proper ESD protection must be used during analysis to prevent damage to sensitive electronic components.

Item Requirement Comments

Data Collection

Record - Claim number - Dealer number - VIN number - Receive date - Occurrence date - Complete barcode - Customer contention - MQ's analysis and notes

External Visual Inspection Inspect for signs of damage or tampering of overall part

Initial Power Up Test Less 10V and review / save entire EEPROM data

Full Power Up Test

- Clear codes, if present and check operation at minimum of 13V

- Review / save entire EEPROM data - In addition, minimum of 10 power cycles and

save EEPROM when a failure occurs

Low and High Temp Test

- Maximum low temp @ -40C - Minimum high temp @ 85C - Minimum of 1hr soak @ each temperature - Power up minimum of 13V - Minimum of 5 power cycle @ each temperature

Internal Visual Inspection

- Inspect for signs of PCB / component / solder abnormality

- A-B-A swap to confirm failure follow component - Picture of internal defect - X-ray of part prior to destruction of housing

removal

X-ray only if housing requires

destruction in order to conduct internal visual

inspectionPart Storage of NTF and

Failed Parts

Minimum of one year

Reporting to Honda

- Weekly status update to all three facilities (HMA, HAM, and HCM)

- Include data collection requirements - Visual inspection and analysis result - Root cause and countermeasure activities - IPP tag number for implemented countermeasures - If failure effects vehicle performance (notify

Honda immediately)

HSQM-0109 Page 1/1 06/01/10

Suspension Damper Assemblies Minimum Test Requirements

Suspension Damper Assemblies Minimum Test Requirements

The table below contains the minimum requirements for handling / analysis / testing of suspension damper assemblies.

Item Requirement Comments

Data Collection

Record - Claim number - Dealer number - VIN number - Receive date - Occurrence date - Customer contention

External Visual Inspection Inspect for signs of damage or tampering of overall part Functional Test

- Damping force check - Gas reaction check - Rod acceleration test - Swish test - Hammer test spring noise

Internal Inspection - Oil volume and contamination analysis - Teardown and valving analysis

Dimensional Layout Full component dimensional layout When applicable

Vehicle Test Any abnormal noise When applicable

Low and High Temp Test Per drawing specification When applicable

Reporting to Honda

- Include data collection requirements - Visual inspection and analysis result - Root cause and countermeasure activities - IPP tag number for implemented

countermeasures - If failure effects vehicle performance (notify

Honda immediately)

HSQM-0110 Page 1/1 06/01/10

Non-Destructive Testing (NDT) Requirements

HSQM-0118 Page 1 06/01/2012

Purpose The following pages provide details on Honda’s requirements regarding Non-

Destructive testing (NDT).

Resistance / Spot Welding

NDT Requirements is an alternative to Driver Checking (ONLY on High Strength Steel 780 MPa or higher) and Full Destruct Testing.

New Model

Month Requirement Conditions to Move Forward

All Pre-PP events

Measurement Reliability – Min. 90% *Correlation Accuracy

• NDT correlation with HSS Driver Check and Destruct first and last piece per New Model build with good results.

• Data recorded and reported.

Mass Production Month Requirement Conditions to Move Forward

0 to 3


• NDT correlation with Driver Check and/or Destruct 1 per shift for entire time period and minimum 10 consecutive good results.

• Use NDT method three times per shift. • Data recorded and reported, if requested by plant

Parts Quality.

3 to 6


• NDT correlation with Driver Check and/or Destruct 1 per day with minimum 10 consecutive good results.


Parts Quality.

6 to 9


• NDT correlation with Driver Check and/or Destruct 1 per week with 10 consecutive good results.


Parts Quality.

9 to 12


• NDT correlation with Driver Check and/or Destruct 1 per month with 10 consecutive good results.


Parts Quality.

12 + MP Life


• NDT correlation with Driver Check and/or Destruct 1 every three months.


Parts Quality.

* Correlation Accuracy: % of welds identified by NDT as NG actually confirmed NG by destruct.

Note - 100% all NG welds identified by destruct test must show NG on NDT correlation.


HSQM-0118 Page 2 06/01/2012

Resistance / Spot Welding (continued)

Any correlation results not meeting the requirements must be sent to Parts Quality for review. Results will be evaluated, countermeasure evaluated and path forward approved by Parts Quality. Note - NDT does not replace Destruct testing, it only reduces frequency. Destruct is still used to correctly identify small and cold welds as defined by HES requirement. NDT is intended to reduce the scrap associated with driver checks. A supplier is considered certified to use NDT at a specific location once they have completed the full one-year correlation on a range of parts and approval is granted by Parts Quality.

Additional Requirements

• The supplier must complete the full one-year correlation on a range of parts. The range must include different variables such as material types, thicknesses, stack up etc. This range is to be approved by Honda Parts Quality department.

• Individual parts having more than 50 welds must have a correlation plan submitted to

Parts Quality to negotiate frequency during the 0-9 month period of Mass Production. • There must be a reference check at start of each shift (based on Actual Good and No

Good part samples or coupons) to ensure the NDT method is working properly. • The weld integrity must be confirmed after any weld parameter changes, using NDT

and supporting the NDT confirmation with a driver check or destruct test (refer to the Change Point Control procedure - IPP / IPPAAR requirements).

• In the event of NDT equipment downtime, certification lapse, or lack of certified

operator; the supplier is required to report the condition to Parts Quality and follow the Weld MPR for destruct guidelines.

• The supplier must achieve and maintain inspector certification (able to program) per

equipment maker guidelines. • The supplier must have qualified / trained inspectors on site during all supplier

production hours and shifts. Re-qualification every six months must be part of the inspector training program.

• The training program and training records of each operator must be maintained and

available to be reviewed and audited by Parts Quality. • The supplier must follow NDT equipment manufacturer recommended certification

method and frequency. • After the supplier is certified for NDT process, all New Models are required to follow

the New Model correlation requirement.


HSQM-0118 Page 3 06/01/2012

Additional Requirements (continued)

• Once the NDT process has been proven and approval granted by a plant for initial model or range, correlations checks must be conducted when material thickness, stack ups, and welding parameters are different from initial model or range. Using the 0-3 month criteria. Parts Quality can reserve the right to request a full 1-year re-approval if the supplier :

- Changes NDT equipment - Has a certification lapse - Does not follow NDT protocol - Has false positive readings (resulting in repeat failures at customer)

Projection Welding

NDT Requirements / test method alternatives to Destruct for Projection welds (hex and square nuts). Method – Manual Torque (click) wrench • Torque (click) wrench must be set at no lower than HES (B-031-03) requirement,

including allowance for equipment and technique tolerance. Wrench torque setting should not exceed 10% above HES spec. Reference HES table and example below.

• Dedicated torque wrench must be allocated for each size weld nut. The wrench must

be labeled and/or uniquely identified. • Calibration of each wrench must be conducted at start of each shift and documented. • Part must be nested and locked in a secure fixture. • Frequency of NDT – use NDT method three times per shift for all weld nuts on each

part. Anytime a weld parameter, that could affect the quality of the weld, is changed - a NDT must be performed.

HES Table

D x P Strength of Weld (min) N – m {c kgf – cm} (Types A & B) 4 x 0.7

24.52 {250} 5 x 0.8 6 x 1.0 34.32 {350}8 x 1.25 44.13 {450}10 x 1.25 58.84 {600}12 x 1.25 78.45 {800}

Example D x P HES Value Equipment Tol. Torque (Click) Setting On Wrench

5 x 0.8 24.52 + / - .075 Min. 25.27

• NDT method can also be used to guarantee stock during sort and containment process.

Document Type Requirement


‐ Record of change points

‐IPP Control

‐Inspection data attached to IPP

20 years

Drawing and spec sheets

Obsolete and date of changes

Review and implementation of engineering changes

20 years

Internal Audits ‐ all types 20 years

Lot Control Traceability

Abnormal situation/repair logs

Change point details

Components (lot with data)

Manufacturing history (ex. process conditons, methods, dies, machines and equipment in each step of the

process including inspection)

Inspection results ‐ receiving, in process and final by lot

Materials (lot with data)

Mixed lot parts

Production date/shift/associates Repair/reworked parts

Shipping records

20 years

Maintenance Records (manufacturing equipment and tooling)

Preventive maintenance

Unplanned maintenance

Honda owned tooling asset records

Manufacturing equipment checksheets

20 years

Measuring devices (active and scrapped)

Calibration records

Repair records

Device maintenance records

20 years

Operation Standards

Work instructions

Quality Alerts issued

Poka yoke fixture check sheets

Red rabbit part check sheets

20 years

Parts Inspection Standards

Receiving inspection records

In Process inspection records (including first piece confirmation)

Final inspection records

20 years

Quality Control documents, other

FMEA

PQCT

NM developmment (PACV and MPR confirmation)

Honda TR countermeasures and 5P

20 years

Sub Supplier

Audit record of sub‐suppliers (tier 2 or lower suppliers)

Change point history

Product lot control

Quality problem history with corrective and preventive actions

Tier 1 suppliers are responsible for all sub‐supplier lot control/traceability retention

20 years

Training and Quality Education

Training records

Associates' knowledge and skills competency assessments

20 years

Trouble CM (internal and external)

‐ Non‐conforming parts history with root cause analysis, corrective and preventive actions taken

20 years

NA SQM Supplier Record Retention Requirement Matrix

HSQM‐Reference 04/03/17

Honda Supplier Quality Manual Revision Information List Content Revision 04/01/2019 Issued by North American Supplier QD

Revision Information Page1/2 04/01/2019

The Honda Supplier Quality Manual applies to all North American Honda plants and their suppliers. Controlled Documents

Document Name Control Number

Approval Date

Change Description

HSQM Master List (Content) HSQM-0001 04/01/2019 Changes/additions/deletions etc.

Quality Control Regulations and Minimum Quality System Requirements HSQM-0002 04/01/2019 Updated conformance to 9001 standard and Suspect and nonconforming parts

SAP Components HSQM-0016 04/01/2019 Extensively Revised PQCT Procedure HSQM-0021 04/01/2019 Added predicted failure modes Part Approval Requirements HSQM-0027 04/01/2019 P-4 split into PA-4.1 & PA-4.2 Traceability & Lot Control HSQM-0028 04/01/2019 Further defined Bar Code requirements

Inspection Data HQM-0032 04/01/2019 Removed 15yr Record Retention req. to match Record Retention Matrix

Part Validation (PV) Testing Procedure HSQM-0033 04/01/2019 PA-4 changed to PA-4.1 and PA-4.2 PV Testing Schedule and Results Summary Form HSQM-0034 04/01/2019 Extensively Revised PV Testing Schedule and Results Summary Form Operation Standard HSQM-0035 04/01/2019 Deleted – New form and process, this is now obsolete Change Point Control HSQM-0041 04/01/2019 Added #13 Tariff

Minimum Processing Requirements HSQM-0060 04/01/2019 Added Traceability, removed word “Injection” from molding MPR and removed Hyperlink to MPR Checklist

PV Testing Risk Analysis Form Guidelines HSQM-0072 04/01/2019 Extensively Revised SpeCla Procedure Surface Surface Finish HSQM-0075 04/01/2019 Name Revised Gloss Meter Correlation Requirements HSQM-0077 04/01/2019 Updated Department Name from NASPD to NA SQD Minimum Process Requirements Injection Molding Check sheet HSQM-0079 04/01/2019 “Audited by” and Follow up Actions Minimum Process Requirements Stamping Check sheet HSQM-0081 04/01/2019 Many Changes - See blue text throughout Minimum Process Requirements Wire Harness and Electrical Connection Check sheet

HSQM-0082 04/01/2019 Updated legend and added scope, various corrections throughout – See blue text in document for change points

Minimum Process Requirements Check sheet Error Proofing HSQM-0119 04/01/2019 Clarification for Auto Lighting – No New Requirements Minimum Process Requirements Leak Test Check sheet HSQM-0123 04/01/2019 Many changes

Preface HSQM-0126 04/01/2019 Initial Issue

Structure of SQM HSQM-0127 04/01/2019 Initial Issue

SQM Outline HSQM-0128 04/01/2019 Initial Issue

Designation of Quality Rep. HSQM-0129 04/01/2019 Initial Issue

Supplier Quality Audit QAV HSQM-0130 04/01/2019 Initial Issue

Minimum Process Requirements Traceability HSQM-0131 04/01/2019 Initial Issue

Sourcing QAV HSQM-Ref 04/01/2019 Initial Issue

Revision Information Page2/2 04/01/2019


Approval Date

Change Description

Table of Findings HSQM-Ref 04/01/2019 Initial Issue Auditor Report HSQM-Ref 04/01/2019 Initial Issue CRF (Counter Measure request Form) HSQM-Ref 04/01/2019 Updated Honda use box

Administrative Changes

MPR Wire Harness updated to include Electrical Connection Multiple 04/01/2019 Various locations through-out document

Acronyms and Definitions

HSQM-0056 1/6 04/01/17

Term

Definition "A" Surface High critical appearance areas 4KOQ Four Keys to Outstanding Quality 5P 5 Principles for Problem Solving - a problem cause analysis form used by Honda 5S A visual workplace management term - sort, set in order, shine, standardize and sustain AEP Anna Engine Plant AF Assembly Frame or Assembly Department AH American Honda AIAG Automotive Industry Action Group AOI Automated Optical Inspection

Approved Supplier A supplier that has completed the Purchasing Division requirements for Honda suppliers and is listed on the Purchasing Division list of approved suppliers

A-rank Those problems that create a non-compliance to government regulations. Those problems that could lead to sudden loss of functions such as cannot turn, stop, go or safety features.

ASN Advance Shipping Notice

Associate Generic term used for an employee. Applies to all levels of responsibility including production, support, and management

ASTM American Society for Testing and Materials Baan Inventory system used by Honda BOM Bill of Material BPL Buhin (parts) Project Leader – PH Project Leader B-rank Those functional items other than A rank that could impair the performance of products

Bully Test An activity to test the toughness of a process or process control measures by purposefully inputting human error or other types of extreme variation.

C/M Countermeasure CBT Computer Based Training

CBU Completed Body Unit (a completed automobile, motorcycle or ATV) or Complete Built Unit

CC Consolidation Center (e.g. MEI, NKP, Nissin, NSE, SEE, NEX or SPS) CCP Critical Control Points CFR Code of Federal Regulations CIOO Sayama International Overseas Operations Class 1, 2 or 3 A method Honda uses to measure supplier quality performance CMM Coordinate Measuring Machine CMVSS Canadian Motor Vehicle Safety Standard Containment The act of identifying and controlling suspect parts/nonconforming, materials, or products Controlled Documents/Data

Documents or data that convey approved, current quality system information to a defined set of users

COP Conformity of Production (European Regulations)

Countermeasure (C/M) The set of actions to analyze, identify and permanently eliminate the root cause(s) of a non-compliance or non-conformance

CPCS Change Point Control System (a portal application for IPPAAR/IPP) CPG Cost Planning Group/Cost Procurement Group CQ Challenge Quality C-rank Those items other than A, B, or R rank CRF Countermeasure Request Form

Critical Process A process that, if not performed according to the operation standard, could result in an A-rank problem

Css Sayama plant in Japan


HSQM-0056 2/6 04/01/17

Term Definition D/C Design Change or Engineering Change D/T Down time D0/D1 R& D evaluation events DCR Design Change Request (see CRF) DDV Durability Data Vehicles DFMEA Design Failure Mode Effect Analysis DHEC Honda engine plant in China Direct Supplier The supplier that ships directly to Honda DPMO Defects per Million (solder) Opportunities

DSPS Domestic Supply Parts Supplier - a DSPS part is purchased by Honda from one supplier and supplied to another supplier for assembly and shipment to Honda

DTR Domestic Trouble Report or Delivery Trouble Report EC Regulations European Community Regulations EDI Label The standard computer generated label required by Honda on all part containers EDV Emission Data Vehicles EGA Honda Engineering North America EGJ Honda Engineering of Japan

EIN Engine Identification Number - unique number assigned by the manufacturer to an engine for registration and identification

ELP East Liberty Auto Plant Emission Certification Government requirement for Approval of Sales EQ Engine Quality ESD Electro Static Discharge FGE Factory Guest Engineer Field/Market Actions Actions taken in the market to countermeasure problems with Honda products FIFO First In First Out First Lot The initial group of parts manufactured after a change in the part or production process First Lot Producer The original manufacturer of the changing part FMC Full Model Change FMEA Failure Mode Effect Analysis FMVSS Federal Motor Vehicle Safety Standard FTA Fault Tree Analysis or Failure Tree Analysis FTZ Federal Trade Zone Geba CRF evaluation meeting (uchi = internal, soto = external) GHAC Honda plant in China Go 1-1 Honda PH's authorization for the supplier to begin tool design

Go 1-2 Honda PH's authorization for the supplier to purchase long lead raw material for a tool OR to begin rough cutting

Go 2-2 Honda PH's authorization for the supplier to begin tool manufacture Go Release Honda's authorization, to suppliers, to begin specific NM related activities GPCS Global Production Control System HAM Honda of America Mfg., Inc. HATC Honda plant in Thailand HCM Honda of Canada Mfg., Inc. HCPI Honda plant in the Philippines HDM Honda de Mexico Mfg., Inc.

HES Honda Engineering Standards - issued by Honda R&D that prescribe attributes of the products

HGA Honda R&D - Asaka


HSQM-0056 3/6 04/01/17

Term Definition HGH Honda R&D - Asakahigashi HGT Honda R&D - Tochigi HGW Honda R&D - Wako HIN Hull Identification Number HIT Honda International Trading Company HM NMC Honda Motor New Model Center HMA Honda Manufacturing of Alabama, Inc. HMIN / HMI Honda Manufacturing of Indiana, Inc. Honda R&D Honda Research and Development HPE Honda Power Equipment HPPG Honda Precision Parts of Georgia HPM Honda Prospect Motors - Honda plant in Indonesia HRA-C Honda R&D - California HRA-LA Honda R&D - Los Angeles HRA-N Honda R&D – North Carolina HRA-O Honda R&D - Ohio HRA-S Honda R&D – South Carolina HSC Honda South Carolina HSCI Honda Siel Cars India Ltd. HTM Honda Transmission Manufacturing HTR Honda Trouble Report HTR Reply Honda Trouble Report Reply IC Internal Circuit ICT In-Circuit Test IDPS (IPS) International Domestic Parts Supply (International Parts Supply) Importance Rank Evaluates the problem severity

Index A measure of supplier quality performance based on the severity of part problems and the number of parts rejected (Importance Rank + Number of Problems Rank)

In-Process Parts Parts ordered for Material Service's in-process cage (safety stock) Inspection Fixture Device that measures or inspects part dimensional accuracy

Inspection Standard A written document that describes the characteristics to check, the check method and the check frequency

IPP Initial Production Parts IPP Tag The form used to document initial production parts control IPPAAR Initial Production Parts Advance Approval Request IQS Initial Quality Survey ISO International Organization for Standardization ITR International Trouble Report (same as HTR) JIS Japanese Industrial Standard

JMLIT (JMOT) Japan Ministry of Land Infrastructures and Transportation (Japan Ministry of Transportation)

JSPS Japan Supplied Parts Supplier KD Knock Down - Japan Supplied Parts KKD Kumamoto Overseas Operation Plant Kobai Japan PH group Kss Kumamoto plant in Japan (ATV) Legacy An inventory system used by Honda LCNF Lot Control Notification Form LNDD Lot Number Display Detail


HSQM-0056 4/6 04/01/17

Term

Definition

Lot A group of parts manufactured under the same conditions, and with the same sub-components and materials

Lot Control/Traceability

Tracking parts by creating lots, identifying the parts with lot number identification, shipping and using the lots in sequence and linking lot numbers to a VIN, EIN, PSN (product serial number)

LOTO Lock Out Tag Out LPL Large Project Leader M100 Styling data Maker Layout The assignment of a Honda product part to a selected supplier

Manufacturing Instruction (M/I)

Formal, numerically controlled document that allows the manufacturing plant to create product structures or processes unique to its operation. Also, formal method to communicate plant BOM changes

MAP Marysville Auto Plant MIR Market Impact Report MMC Material Management Center MMP Marysville Motorcycle Plant MOOD Hamamatsu Overseas Operational Department MOT (JMLIT) Ministry of Transportation MP Mass Production MPR Minimum Process Requirements MPR Checksheet Form used to verify MPRs are part of manufacturing processes MQ Market Quality

MQS Manufacturing Quality Standard – sometimes referred to as Manufacturing Quality Requirement

MS Material Service MSD Moisture Sensitive Devices Mss Hamamatsu plant in Japan (Motorcycle) MTOC Model Type Option Color NACP North American Cost Procurement NAP North American Purchasing Nariyuki Step by step breakdown that shows results of individual activities leading to the total effect NARS North America Reporting System

National Standards The primary reference standards kept by the US Bureau of Standards that serve as the basis for calibrations of equipment, measuring instruments and test devices

NDR New Model Delivery Trouble Report

NIST National Institute of Standards and Technology - the body that maintains highly sensitive equipment to calibrate weights and measures

NM New Model NMC New Model Center NMD New Model Department NMR New Model Review NMS New Model Section NMTG New Model Technical Group NPP Not A Parts Problem NQR New Model Quality Trouble Report NTF No Trouble Found

Nuisance Value Denotes problem impact to the plant by accumulating one point per Honda hour to contain or repair the problem


HSQM-0056 5/6 04/01/17

Term Definition OEE Operation Equipment Efficiency

OEM Original Equipment Manufacturer (parts that have a Honda part number and stay with the completed unit)

OOP Overseas Operation Plant P.I.C. Person In Charge P/C/M Permanent Countermeasure P/L Project Leader PACD Parts Appearance Coordination Document PACT Process Assurance Capability Tracking PC Production Control Department PCB Printed Circuit Board PDCA Plan Do Check Action PDF Process Display Form PDI Pre-delivery Inspection PEDD Product Engineering Development Department PETD Product Engineering Test Department PFMEA Process Failure Mode Effect Analysis PH NM Purchasing New Model PH or PUR Purchasing

PI Production Instruction – document used to control and communicate product build schedules, lot size, model, type, color (MTC), and / or special instructions

PICS An inventory system used by Honda - Parts Inventory Control System PIS Process Inspection Standard Planned SVR A Supplier Visit Report based on an annual plan PLC Programmable Logic Controller PM Preventive Maintenance or Parts Maturation

PO Purchase Order - Purchasing Division document used to communicate product amounts, price, specifications, and timing to suppliers

Poka-Yoke or Error-Proof Device

In the process sensors or confirmation devices, that examine all parts produced by the process, for a specific characteristic (e.g. to detect missing or mis-installed components)

Portal/Honda Supply Team Portal

An electronic tool for communication between Honda and suppliers, via the internet

PP Parts Procurement or Pre-Production

PPA Potential Problem Analysis - sheet to communicate and document potential problems to suppliers for countermeasure/prevention activity

PPE Personal Protective Equipment PPH Past Problem History PPHU Problems Per Hundred Units PPS (PPMD) Parts Procurement PQ Parts Quality / Purchasing Quality (PM and PP at HCM)

PQCT (Control Plan) Process Quality Control Table - defines control methods for manufacturing conditions and quality characteristics for each item requiring quality control from material receiving to manufacturing and shipping

PQS Part Quality Standard – Parts Quality Section – Product Quality Survey PSN Product Serial Number PTC Problem Tracking Chart Q10 Gap and flushness activity


HSQM-0056 6/6 04/01/17

Term

Definition QAN# Quality Assurance Notification Number QAV Quality Assurance Visit QC Quality Control QCD Quality - Cost Delivery QPL Quality Project Leader QS Quality System QSS Quality Stabilization Sheet

Quality Standards Written criteria beyond design specifications that are used to judge acceptability. A quality standard contains information that supplements the part drawing in order to define certain required control characteristics

Rank To assign severity to a product problem RCC Returnable Control Center

Repair Action taken on a non-conforming product so that it will fulfill the intended usage requirements, although it may not conform to the originally specified requirements

Rework Action taken on a non-conforming product so that it will fulfill the specified requirements RFI Request for Information RFQ Request for Quote RFS Regardless of Feature Size RH Relative Humidity R-Rank Used for rejections of castings or forgings at the machining source S100/S200 Styling data SA Situation Analysis SAP Specified Action Plan SD Supplier Development Group SIOO Suzuka International Overseas Operations SMT Surface Mount SpeCla Specification Clarification SPR Supplier Performance Report SPS Supplier Part Schedule SQCDM Safety - Quality - Cost - Delivery - Morale SQD Supplier Quality & Delivery SQM Supplier Quality Manual Sss Suzuka Plant in Japan Straight Ship A unit that is OK to send to shipping directly off the production line Sub-supplier Any supplier at a lower tier than the supplier being considered Sudden Loss of Function

Any situation where the customer may lose a safety function of their vehicle without prior awareness or warning of a problem

SVR Supplier Visit Report T/C/M Temporary Countermeasure TDS Technical Data Sheet

Traceability The ability to link a measurement to a national or international standard. Also, the ability to link a lot of material or parts to a finished product

VA Value added or cost down activity

VIN Vehicle Identification Number - a unique number assigned by the manufacturer to a vehicle for registration and identification

VQD Vehicle Quality Department W/B White Body - welded assembly of body components WIP Work In Progress WRP Warranty Recovery Program YTD Year To Date

HSQM Continuous Improvement Flow

SQM Revision Suggestions/Ideas

SQD

SQD creates draft document and posts for Plant review

Plants review draft document and respond to SQD

HSQM Continuous Improvement

•The HSQM is developed by a continuous improvement method (input, evaluation, decision making, etc.) with stakeholders and users making beneficial changes

•Maintaining the effectiveness of the HSQM depends on the continual input and evaluation from all North America Honda plants

•There are review meetings to discuss feedback from suppliers, PQ associates, etc.

SQD adjusts document as necessary

Each Honda Plant notifies SQD of agreement SQDT posts SQM revision on

the Hondaweb

SQD Formal Distribution •Notify suppliers (all portal users)

•Notify Plant SQM window associates

HSQM-0059 1/1 11/01/2011

Plant Codes

HSQM - Reference Page 1/1 04/01/18

Below is a list of plant codes/identifiers used by Honda to indicate various plants. These codes are used by the applications available on the Honda Supply Team Portal.

Plant Name AEP Anna Engine Plant AHM American Honda Motor ELP East Liberty Automobile Plant HCL Honda de Mexico Celaya HCM1 Honda of Canada Manufacturing Inc. – Plant 1 HCM2 Honda of Canada Manufacturing Inc. – Plant 2 HCM3 Honda of Canada Manufacturing Inc. – Plant 3 HDM Honda de Mexico SA DE CV HMA Honda Manufacturing of Alabama HMIN / HMI Honda Manufacturing of Indiana HPE Honda Power Equipment HPPG / HPG Honda Precision Parts of Georgia HSC1 Honda of South Carolina – Plant 1 HSC2 Honda of South Carolina – Plant 2 HTA Honda Trading HTM Honda Transmission Manufacturing IPS International Parts Supply IPS-HDM North American Logistics IPS-Other North American Logistics MAP Marysville Automobile Plant NAL North American Logistics NAP North American Purchasing PMC Performance Manufacturing Center HSP Honda Supply Parts MPS Mexico Parts Supply

Some of the HondaWeb applications also use codes within that specific system to identify a particular plant. For example Prior to 2017, NARS Trouble Report Number AQMP123456 – the “A” indicates Marysville Auto Plant After 2017, the Plant Code wil be the Plant Name. IPPAAR Tracking Number 12345V – the “V” indicates Marysville Auto Plant The below table lists the Honda plants and related system codes.

Plant CPCS NARS AEP N N ELP E T HCL J J HCM L C HDM Q Q HMA X V HMIN Z I HPE K K

HPPG H H HSC O O HTM B B IPS I P

MAP V A PMC Y Y HSP Z

Note – see the EDI Manual for ordering codes. That manual can be located on the Honda Supply Team Portal Reference tab.

Factory Guest Engineer (FGE)

HSQM-0013 Page 1/2 06/03/02

FGE The FGE program allows suppliers access to build events at Honda, during

new model development and mass production when necessary.

Items covered during a FGE meeting are intended to ensure a smooth NM introduction and resolve (C/M) current MP issues. This is done by improving

• Safety • IQS related problems • Line down part problems • Recurring rejects • Straight ship part problems • Communication between suppliers and Honda

The FGE program gives the supplier a better understanding of the part to unit

relationship and helps the supplier understand the overall impact of a part problem and the impact to other Honda departments.

Supplier Selection

The decision to select suppliers for the FGE program are based on, but not limited to • Current MP issues • New supplier to Honda • Part problems found at previous trial event at Honda • Part maturation concerns • Overdue part problem tracking charts or C/Ms • Part rank • IQS concern part • Warranty claims • Critical fit and finish items

FGE Associate Selection

The supplier and Honda select the FGE representative together. The following provides a guideline for selecting the appropriate associate. • Quality engineer or quality control staff member • Supplier quality and production system knowledge • NM/part development experience • Understands the concept that “quality is built into the process and not

inspected in” • Has the authority to obtain manpower from the supplier or a temporary

service for sort or repair if needed, to start the corrective action at the supplier

Factory Guest Engineer (FGE)

HSQM-0013 Page 2/2 06/03/02

Benefits and Goals

The following are some benefits and goals of the FGE program. • Allow suppliers to view and touch units/parts • Generate CRFs (countermeasure request forms) based on the prototype

vehicle GO release • PQ can review concerns directly with suppliers • Provide an opportunity for the supplier and Honda associates to meet and

discuss issues • Check mating part fit • Confirm critical data points • Confirm supplier process control for problem items • Supplier brings in part data for each build, for review • Confirm C/Ms at each event

Supplier Quality Performance Rating

HSQM-0010

03/12/2009

Background Honda Purchasing and/or Quality groups go through the process of measuring

suppliers' quality performance. This process has two parts - forming the ratings and Honda subsequent actions.

Note - this is the "Q" rating in Honda's SQCDM process for the maker layout selection process.

Forming the Ratings

The table below shows how the ratings are formed.

Stage Description

1

IPM$ (Index Per Million Dollars of Parts Received) is calculated using this formula • Dollar Value of Parts Received = Purchased Value - Honda Supplied Parts Value • QIPM$ = Quality Index / Dollar Value of Parts Received X 1,000,000 • W$PM$= WRP + CQ + Recall + PUD divided by sales multiplied by 1,000,000

2

Suppliers are grouped into type categories

• AP - Assembler/Painter/Processor • CA - Casting • CC - Complex Component • CS - Complex Stamping • EL - Electrical • F - Fasteners • FF – Forged/Formed • MC - Machining • PA - Plastic Appearance • PNA - Plastic Non-Appearance • R - Rubber • SC - Simple Component • SS - Simple Stamping • ST - Soft Trim

Note – Each supplier is assigned a commodity/category by CPG. Each supplier is placed in one category only. The category placement is by the six-digit supplier number.


HSQM-0010

03/12/2009

Stage Class Ranking calculation Description

3

QIPM$ Calculate the average QIPM$ for each category • Better than half the average - tend to be Class 1 • Worse than twice the average - tend to be Class 3 WIPM$ • Warranty Index divided by sales multiplied by 1,000,000 • Warranty Index class ranking. < half the mean is a class 1, = or > half of mean but

not to exceed 2X mean is a class 2, > two times the mean is a class 3 W$PM$ • Warranty dollars recovered (CQ+WRP+ Recall + PUD) divided by sales multiplied

by1,000,000 • Warranty $ class ranking. $0 = Class 1, = or < mean Class 2, > mean class 3 • Supplier warranty class rank will be the worst of the two, WIPM$ or W$PM$ Note - it is possible for a category to have all suppliers rated as the same class.

4

Honda management reviews the supplier's quality and warranty performance for the last 12 months. Honda senior management may change a supplier's rating based on actual performance (e.g. move from a class 2 to class 3).

Performance factors include • Failure to meet Minimum Process Requirements (MPR) • Response speed • Cooperation • Total impact • Other (e.g. NM development)

5 Purchasing makes final approval of the rating list and distributes to purchasing and quality departments throughout Honda.


HSQM-0010

03/12/2009

Honda Subsequent Actions

Honda uses the supplier quality and warranty performance rating information to make decisions to initiate supplier improvement actions. Decisions to initiate actions are based on available information and management judgment. Actions are initiated by individual Honda facilities as appropriate. PH Division also considers Delivered Quality and Warranty supplier class ranking when awarding business. • Class 1 - consider primary for additional business • Class 2 - consider for continued business. Requires additional

documentation for expanding business. • Class 3 - consider for reduction in business. Requires documented

justification for continued or increased business. Negotiate fundamental business system improvements and resources.

Honda Supplier Quality Manual Master List Content Revision 04/01/2019 Issued by North American Supplier QD Group

HSQM-0001 Page1/10 04/01/2019

The Honda Supplier Quality Manual applies to all North American Honda plants and their suppliers. Current revision change points are in blue bold text Controlled Documents


Approval Date

Change Description

HSQM Master List (Content) HSQM-0001 04/01/2019 Updated for document revisions, additions and deletions Quality Control Regulations and Minimum Quality System Requirements

HSQM-0002 07/01/2015 G- Rank removed

Quality Control Regulations and Minimum Quality System Requirements

HSQM-0002 04/03/2017 Suspect and Nonconforming Part and Abnormal Process

Quality Control Regulations and Minimum Quality System Requirements

HSQM-0002 04/01/2019 Updated conformance to 9001 standard and Suspect and nonconforming parts

Best Practices - Top Management HSQM-0003 07/01/2015 REMOVEDBest Practices - SAP Team HSQM-0004 07/01/2015 REMOVEDBest Practices - PFMEA Team HSQM-0005 07/01/2015 REMOVEDBest Practices - PQCT Team HSQM-0006 07/01/2015 REMOVEDPortal and PQTS Overview HSQM-0007 07/13/2007 Deleted – CBT, help and training are available in NARS Index System HSQM-0008 04/01/2018 Rank Determination Table updated

NM HTRs HSQM-0009 07/15/2005 Deleted – information is contained within the Index procedure

Supplier Quality Performance Rating HSQM-0010 03/12/2009 Added various information about Warranty Index Warranty Recovery Program (WRP) HSQM-0011 07/15/2005 Deleted QAV Procedure HSQM-0012 07/01/2015 REMOVED Factory Guest Engineer (FGE) HSQM-0013 06/03/2002 Initial issue

E Timing HSQM-0014 06/01/2010 Deleted – included in E Requirements

Specified Action Plan (SAP) Procedure HSQM-0015 06/03/2002 Initial issue SAP Components HSQM-0016 04/01/2019 Extensively Revised

Countermeasure Request Form (CRF) Procedure HSQM-0017 07/01/2015 Submission location updated to reflect differences in process


HSQM-0001 Page2/10 04/01/2019


Approval Date

Change Description

PFMEA Procedure HSQM-0018 04/01/2015 No Revision PFMEA Form HSQM-0019 04/01/2015 REMOVED PFMEA Operation Standard HSQM-0020 04/01/2015 REMOVED PQCT Procedure HSQM-0021 04/01/2019 Added predicted failure modes

PQCT Form and Operation Standard HSQM-0022 06/01/2012 Changed Design Rank from N to NH to match Honda drawings

PQCT Form Operation Standard HSQM-0023 11/01/2011 Deleted – combined into PQCT form Process Inspection Standards (PIS) Procedure HSQM-0024 06/01/2010 Deleted, Replaced by PAC-V PIS Form HSQM-0025 06/01/2010 Deleted, Replaced by PAC-V Potential Problem Analysis (PPA) Procedure HSQM-0026 06/01/2010 Deleted, Replaced by PAC-V Part Approval Requirements HSQM-0027 04/01/2019 P-4 split into PA-4.1 & PA-4.2 Traceability & Lot Control HSQM-0028 04/01/2019 Further defined Bar Code requirements LNDD Form HSQM-0029 06/01/2012 Converted from Microsoft Word to Excel Bar Code Standard HSQM-0030 07/01/2015 2D, QR & Linear Updates Part Quality Standard Procedure HSQM-0031 04/01/2015 Removed

Inspection Data Procedure HSQM-0032 07/01/2015 Removed 15yr Record Retention req. to match Record Retention Matrix

Part Validation (PV) Testing Procedure HSQM-0033 04/01/2019 PA-4 changed to PA-4.1 and PA-4.2 PV Testing Schedule and Results Summary Form

HSQM-0034 04/01/2019 Extensively Revised


HSQM-0001 Page3/10 04/01/2019


Approval Date

Change Description

PV Testing Schedule and Results Summary Form Operation Standard

HSQM-0035 04/01/2019 Deleted – New for and process, this form is now obsolete

New Model Receiving Inspection HSQM-0036 11/01/2010 Extensive Changes. See Italicized information in procedure.

Limit Sample HSQM-0037 07/01/2015 Two Sets info amended Non-conforming Product Procedure HSQM-0038 05/01/2011 Added text regarding corrective action effectiveness. 5 Principles for Problem Solving Procedure HSQM-0039 07/01/2015 G-Rank removed 5P Form HSQM-0040 04/01/2018 5P evaluation tab added Change Point Control HSQM-0041 04/01/2019 Added #13 Tariff IPPAAR Form HSQM-0042 07/10/2006 Updated form layout for CPCS changes IPPAAR Form Operation Standard HSQM-0043 03/12/2009 Updated appearance. IPP Tag HSQM-0044 07/10/2006 Updated form layout for CPCS changes

IPP Tag Operation Standard HSQM-0045 03/12/2009 Updated appearance. Changed wording of ‘Acceptance Inspection Judgment’ box.

"A" Lot Control Tag Procedure HSQM-0046 07/15/2005 Deleted – the form is discontinued Regular Lot Control Tag Procedure HSQM-0047 07/01/2015 REMOVED Identification Control Procedure HSQM-0048 07/10/2006 Updated color table Inspection Fixture Design Guideline HSQM-0049 06/01/2012 Page 17 – removed “concept” from form name Inspection Fixture Concept Form HSQM-0050 05/01/2015 Extensively revised – Added Cost Inspection Fixture Approval Form HSQM-0051 05/01/2011 Extensively revised -

Technical Part Review HSQM-0052 06/01/2012 Changed from five to three phases, updated Timing and Reviews section, updated General Activity Details chart

Technical Part Review Three Step Process HSQM-0053 07/06/2004 Deleted Minimum Tooling Specifications for SpeCla Parts Surface Finish

HSQM-0054 04/01/2019 Name Revised

Master Sample Development HSQM-0055 07/13/2007 Added reference to NMS and HGT


HSQM-0001 Page4/10 04/01/2019


Approval Date

Change Description

Acronyms and Definitions HSQM-0056 04/01/2017 SQD – Added (Supplier Quality & Delivery Forms Ordering IPP and Lot Control HSQM-0057 07/01/2015 REMOVED IPP Order Form HSQM-0058 11/01/2011 Deleted – forms and labels are now ordered on-line

HSQM Continuous Improvement Flow HSQM-0059 11/01/2011 Removed signature box, all SQM approvals are tracked electronically and not on individual documents

Minimum Process Requirements Procedure HSQM-0060 04/01/2016 Revised E1 & E2 to PA2, PA3, PA4 or PA5

Minimum Processing Requirements HSQM-0060 04/01/2019 Added Traceability, removed word “Injection” from molding MPR and removed Hyperlink to MPR Checklist

Controlled Containment HSQM-0061 04/01/2016 Under “Honda actions:” Changed “holds” to “hold Minimum Process Requirements Torque Check sheet

HSQM-0062 03/12/2009 Extensive changes. See italicized information on procedure.

Minimum Process Requirements Weld Check sheet

HSQM-0063 06/01/2012 Added information for NDT (non-destruct testing) – replaced item 4 in the Quality Confirmation section

Minimum Process Requirements Casting Check sheet

HSQM-0064 11/01/2011 Added cooling system section, updated pouring section

Minimum Process Requirements Machining Check sheet

HSQM-0065 06/01/2012 Added line 15

Minimum Process Requirements Heat Treatment Check sheet

HSQM-0066 03/12/2009 Extensive changes. See italicized information on procedure.


HSQM-0001 Page5/10 04/01/2019


Approval Date

Change Description

Electronic Sort Label HSQM-0067 07/01/2015 Requirement added. Reminders & Clarifications removed. Title changed to “Sort Label”

E Requirements HSQM-0068 06/01/2010 Added PAC-V into appropriate areas. Deleted the PPA / PIS items and incorporated E-timing information

Process Display Form (PDF) HSQM-0069 07/06/2004 Initial issue

Minimum Process Requirements General Check sheet

HSQM-0070 03/12/2009 Deleted – This information is covered by the Minimum Quality System Requirements (HSQM-0002)

PV Testing Risk Analysis Procedure HSQM-0071 04/01/2016 Revised E1 to PA3/PA4, E2 to PA5

PV Testing Risk Analysis Form Guidelines HSQM-0072 04/01/2019 Extensively Revised

PV Testing Risk Analysis Operation Standard HSQM-0073 03/12/2009 Initial Issue

Minimum Process Requirements Plastic ‘Hot Plate’ Welding Check sheet

HSQM-0074 03/12/2009 Initial Issue

Minimum Process Requirements Plastic ‘Hot Plate’ Welding Check sheet

HSQM-0074 04/03/2017 In Process Inspection – Weld Integrity

SpeCla Procedure Surface Surface Finish HSQM-0075 04/01/2019 Name Revised

Minimum Process Requirements Fluid Fill Procedure

HSQM-0076 06/01/2012 Deleted - same information is included on the check sheet

Gloss Meter Correlation Requirements HSQM-0077 04/01/2019 Updated Department Name from NASPD NA SQD

Minimum Process Requirements PCB Check sheet

HSQM-0078 06/01/2012 Removed “recommended” from Solder Paste Volume and Distribution and Part Connector Terminal Condition sections

Minimum Process Requirements Injection Molding Check sheet

HSQM-0079 04/01/2019 “Audited by” and Follow up Actions


HSQM-0001 Page6/10 04/01/2019

Minimum Process Requirements Painting Check sheet

HSQM-0080 03/12/2009 Extensive changes. See italicized information on procedure


Approval Date

Change Description

Minimum Process Requirements Stamping Check sheet

HSQM-0081 11/01/2011 Many Changes - See blue text throughout

Minimum Process Requirements Wire Harness and Electrical Connection Check sheet

HSQM-0082 04/01/2019Updated legend and added scope, various corrections throughout – See blue text in document for change points

Honda Supply Parts Trouble Management (DSPS/JSPS)

HSQM-0083 07/01/15 Defect Report section modified

DSPS Flow HSQM-0084 07/01/2015 Info removed under Direct Supplier – Tier 1 JSPS Flow HSQM-0085 07/01/2015 Info removed under Direct Supplier – Tier 1 Direct Supplier Defect Report HSQM-0086 11/01/2011 Obsolete Electrode Review Form HSQM-0087 02/01/2006 Changed to a controlled document Minimum Process Requirements Fluid Fill Check sheet

HSQM-0088 09/30/2009 Initial Issue

Challenge Quality Process Overview HSQM-0089 11/01/2011 Initial issue

Texture Indication Map Form HSQM-0090 04/01/2015 Full Replacement Texture Indication Map Form Operation Standard HSQM-0091 09/30/2009 Revision for NANM SpeCla Theme Audio Best Practice HSQM-0092 07/01/2015 REMOVED Minimum Process Requirements Label Check sheet HSQM-0093 10/15/2013 Extensively Revised Minimum Process Requirements Label Check sheet HSQM-0093 04/03/2017 Judgement and Row Status Update Process Assurance Capability Verification (PAC-V)

HSQM-0094 04/01/2018 Added (NARS reports including MIR reports)


HSQM-0094 04/03/2017 Requirements – “Government Regulations” added

Process Assurance Capability Verification (PAC-V) Sheet (Form)

HSQM-0095 04/01/2015 Revisions under Descriptions

Minimum Process Requirements Casting Procedure HSQM-0096 06/01/2012 Deleted - same information is included on the check sheet


HSQM-0001 Page7/10 04/01/2019

Minimum Process Requirements Heat Treatment Procedure



Approval Date

Change Description

Minimum Process Requirements Plastic ‘Hot Plate’ Welding Procedure


Minimum Process Requirements Injection Molding Procedure


Minimum Process Requirements Label Procedure HSQM-0100 06/01/2012 Deleted - same information is included on the check sheet Minimum Process Requirements Machining Procedure


Minimum Process Requirements Painting Procedure


Minimum Process Requirements PCB Procedure HSQM-0103 06/01/2012 Deleted - same information is included on the check sheet Minimum Process Requirements Stamping Procedure


Minimum Process Requirements Torque Procedure


Minimum Process Requirements Weld Procedure HSQM-0106 06/01/2012 Deleted - same information is included on the check sheet Minimum Process Requirements Wire Harness and Electrical Connection Procedure


Minimum Test Requirement Procedure HSQM-0108 06/01/2010 Initial issue Minimum Test Requirements SRS Electronic Assemblies

HSQM-0109 06/01/2010 Initial issue

Minimum Test Requirements Suspension Damper Assemblies


Minimum Test Requirements Electro-Mechanical and Mechanical Assemblies


Minimum Process Requirements Part Marking Procedure



HSQM-0001 Page8/10 04/01/2019


Approval Date

Change Description

Market Part Analysis Requirements HSQM-0115 07/01/2015 REMOVED Non-CQ Process Overview HSQM-0116 07/01/2015 REMOVED Minimum Process Requirements Sonic / Vibration Welding Check sheet


Non-Destructive Testing (NDT) Requirements HSQM-0118 06/01/2012 Initial issue

Minimum Process Requirements Check sheet Error Proofing HSQM-0119 04/01/2019 Many changes – See blue text in document for change points

China Compulsory Certification (CCC) HSQM-0120 02/01/2013 Initial Issue Appearance Part and Tool Detail HSQM-0121 04/01/2015 Initial Issue

IPP Quality Assurance Declaration HSQM-0122 04/01/2015 Initial Issue

Minimum Process Requirements Leak Test Check sheet HSQM-0123 04/01/2019 Many changes Preface HSQM-0126 04-01-2019 Initial IssueStructure of SQM HSQM-0127 04-01-2019 Initial IssueSQM Outline HSQM-0128 04-01-2019 Initial Issue Designation of Quality Rep. HSQM-0129 04-01-2019 Initial Issue Supplier Quality Audit QAV HSQM-0130 04-01-2019 Initial Issue Minimum Process Requirements Traceability HSQM-0131 04/01/2019 Initial Issue

Training Information

Document Name Revision Date

Change Description

Electronic Sort Label 07/13/2007 Deleted – all updated information is included in the CPCS training file on the portal reference page

HCM Supply Part Deviation 07/01/2015 REMOVED

Change Point Control System (CPCS) 07/13/2007 Deleted – all updated information is included in the CPCS training file on the portal reference page


HSQM-0001 Page9/10 04/01/2019

Reference Documents – These documents are designated with “HSQM-Reference” in the footer.

Document Name Revision

Date Change Description

CRF Form 04/01/2019 Added the missing “confidential” mark CRF Form Numbered 06/03/2002 Initial issue

CRF Form Operation Standard 05/01/2011 Added addendum for Power Sports Products (PSP). Addendum includes additional PSP CRF codes.

PPA Form 06/01/2010 Replaced by PACV PPA Form Operation Standard 06/01/2010 Replaced by PACV PPA Op. Standard Numbered 06/01/2010 Replaced by PACV Lot Control Notification Example Form 11/01/2011 Updated description and bullet points Regulation Data Sheet – Example Form 06/03/2002 Initial issue Honda Inspection Data Sheet – Example Form 06/03/2002 Initial issue Receiving Inspection Data Sheet 06/03/2002 Initial issue Operational Excellence Survey – Management 07/15/2005 Moved to NAT Manual Operational Excellence Survey – Quality 07/15/2005 Moved to NAT Manual Operational Excellence Survey – Advanced Quality Planning 07/15/2005 Moved to NAT Manual Operational Excellence Survey – Manufacturing 07/15/2005 Moved to NAT Manual Operational Excellence Survey – Maintenance and Engineering 07/15/2005 Moved to NAT Manual Operational Excellence Survey – HR 07/15/2005 Moved to NAT Manual

New Model Review (NMR) Process 01/08/2007 Removed from manual – moved to separate link on Honda Supply Team Portal, Reference page

Gage R&R Worksheet – Long Method 06/03/2002 Initial issue Gage R&R Worksheet – Short Method 06/03/2002 Initial issue Supplier Part Schedule (SPS) Procedure 06/03/2002 Initial issue SPS Gantt Chart Example 06/03/2002 Initial issue Tooling Release Process 07/10/2006 Deleted – not a common form/process across North America Authorization to Manufacture Tooling/Equipment - Sign-off Sheet - Example Form

07/10/2006 Deleted – not a common form/process across North America

Authorization to Manufacture Tooling/Equipment - Tool Release - Example Form



HSQM-0001 Page10/10 04/01/2019

Authorization to Manufacture Tooling/Equipment Form Operation Standard


Tooling Summary Sheet Blank – Example 11/01/2011 Deleted – not a common form/process across North America Tooling Summary Sheet Numbered – Example 11/01/2011 Deleted – not a common form/process across North America Tooling Summary Sheet - Filled in Example 11/01/2011 Deleted – not a common form/process across North America Tooling Summary Sheet Operation Standard 11/01/2011 Deleted – not a common form/process across North America Tool Trial History Sheet Form 06/03/2002 Initial issue

Part Maturation Definitions 4/3/2017 Updated the Stamping and Welding sheet – No content revision, but formatted in 02/13/2013 SQM revision to fix one line of hidden text

Honda Addresses 07/01/2015 REMOVED Standards Information 07/01/2015 REMOVED HCM Supply Part Deviation Form 07/01/2015 REMOVED HCM Supply Part Deviation Form Operation Standard 07/01/2015 REMOVED SAP Example 01/08/2007 Added generic example Plant Codes 04/01/2018 Added Mexico Part Supply - MPS Minimum Process Requirements 05/01/2011 Corrected spelling of Poka-Yoke IPP and Lot Control Forms Ordering Instructions 11/01/2011 Larger font for website addresses IPP Forms / Label Example 05/01/2011 Deleted Mistake-Error Proofing Guidelines 07/01/2015 REMOVED Record Retention Matrix 04/03/2017 Initial Issue QAV-1 Basic Checklist 04/01/2019 Previously HSQM-0124 – Moved to reference QAV-2 Process Audit Checklist 04/01/2019 Previously HSQM-0125 – Moved to reference CRF (Counter Measure request Form) 04/01/2019 Updated Honda use box Sourcing QAV 04-01-2019 Initial IssueTable of Findings 04-01-2019 Initial Issue Auditor Report 04-01-2019 Initial Issue